Chemical recycling of metal-containing plastics mixtures

ABSTRACT

Processes and facilities for using one or more PET-containing materials as a feedstock to a chemical recycling facility, and in particular a solvolysis facility, are provided herein. The PET-containing materials used as feedstock may comprise a quantity of PET and metal-containing reclaimer co-product. The PET and metal-containing reclaimer co-product may comprise a quantity of plastic articles, plastic flakes, and/or plastic fines, and may be derived from plastic reclaimer separation processes such as eddy current separators. Such metal-containing co-products are generally undesirable or unusable to mechanical PET recycling facilities, and typically are sent to landfills and/or incinerators. However, the processes and facilities described herein make use of the PET and other plastics present in these otherwise undesirable or unusable metal-containing co-products.

BACKGROUND

Waste materials, especially non-biodegradable waste materials, cannegatively impact the environment when disposed of in landfills after asingle use. Thus, from an environmental standpoint, it is desirable torecycle as much waste material as possible. However, there still existstreams of low value waste that are nearly impossible or economicallyunfeasible to recycle with conventional recycling technologies. Inaddition, some conventional recycling processes produce waste streamsthat are themselves not economically feasible to recover or recycle,resulting in additional waste streams that must be disposed of orotherwise handled. For example, plastic reclaimer facilities can producesignificant amounts of waste plastics that are undesirable or unusableby consumers and mechanical recycling facilities. In particular, plasticreclaimer facilities can produce quantities of metal-containingco-products that are undesirable or unusable to mechanical recyclingfacilities but may contain some amount of otherwise desirable or usablePET and/or other plastics. However, these metal-containing co-productsare typically disposed of in landfills and/or incinerators.

Thus, a need exists for a large-scale facility capable of chemicallyrecycling a variety of plastic-containing waste materials recovered fromsuch sources, particularly otherwise undesirable or unusablemetal-containing co-products from a plastic reclaimer facility, in aneconomically viable manner.

SUMMARY

In one aspect, the present technology concerns a method of recycling aplastic waste. Generally, the method comprises: (a) feeding a quantityof PET and metal-containing reclaimer co-product separated from theplastic waste to a chemical recycling facility; and (b) depolymerizingin the chemical recycling facility at least a portion of the PET andmetal-containing reclaimer co-product.

In one aspect, the present technology concerns a method of recycling aplastic waste. Generally, the method comprises (a) feeding a quantity ofPET and metal-containing reclaimer co-product separated from the plasticwaste to a chemical recycling facility. The quantity of metal-containingco-product comprises plastic flakes and at least 0.1 weight percentmetals. The method further comprises (b) depolymerizing in the chemicalrecycling facility at least a portion of the plastic flakes.

In one aspect, the present technology concerns a method of recycling aplastic waste. Generally, the method comprises (a) feeding a quantity ofPET and metal-containing reclaimer co-product separated from the plasticwaste to a chemical recycling facility. The quantity of metal-containingco-product comprises plastic articles and at least 0.1 weight percentmetals. The method further comprises (b) depolymerizing in the chemicalrecycling facility at least a portion of the plastic articles.

In one aspect, the present technology concerns a method of recycling aplastic waste. Generally, the method comprises (a) feeding a quantity ofPET and metal-containing reclaimer co-product separated from the plasticwaste to a chemical recycling facility. The quantity of metal-containingco-product comprises plastic fines and at least 0.1 weight percentmetals. The method further comprises (b) depolymerizing in the chemicalrecycling facility at least a portion of the plastic fines.

In one aspect, the present technology concerns the use of a PET andmetal-containing reclaimer co-product as a feedstock to a chemicalrecycling facility.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block flow diagram illustrating the main steps of a processand facility for chemically recycling waste plastic according toembodiments of the present technology;

FIG. 2 is a block flow diagram illustrating a separation process andzone for separating mixed plastic waste according to embodiments of thepresent technology;

FIG. 3 is a block flow diagram illustrating the main steps of a processand facility for PET solvolysis according to embodiments of the presenttechnology;

FIG. 4 is a block flow diagram illustrating typical rPET products andco-products derived from a PET reclaimer facility;

FIG. 5 is a block flow diagram illustrating the main steps of a PETreclaimer process, and the resulting products and co-products producedtherefrom;

FIG. 6 is a block flow diagram illustrating an exemplary liquificationzone of the chemical recycling facility shown in FIG. 1 according toembodiments of the present technology;

FIG. 7 is a block flow diagram illustrating the main steps of apyrolysis process and facility for converting waste plastic into apyrolyzed product streams according to embodiments of the presenttechnology;

FIG. 8A is a block flow diagram illustrating the main steps of anintegrated pyrolysis process and facility and a cracking process andfacility according to embodiments of the present technology;

FIG. 8B is a schematic diagram of a cracking furnace according toembodiments of the present technology;

FIG. 9 is a schematic diagram of a POx reactor according to embodimentsof the present technology; and

FIG. 10 is a schematic diagram illustrating various definitions of theterm “separation efficiency” as used herein.

DETAILED DESCRIPTION

We have discovered new methods and systems for using one or morePET-containing materials from various sources as a feedstock to achemical recycling facility, and in particular a solvolysis facility.More particularly, we have discovered that PET-containing materials usedas feedstock for chemical recycling or solvolysis may include PET andmetal-containing co-products derived from plastic reclaimer facilities.While these metal-containing co-products are generally consideredundesirable or unusable by mechanical recycling facilities, they cancontain some amount of recoverable plastics, and particularly PETplastics in the form of plastic articles, plastic flakes, and/or plasticfines. The methods and systems described herein are capable of usingsuch PET and metal-containing co-products derived from plastic reclaimerfacilities as a feedstock source in chemical recycling facilities andprocesses.

When a numerical sequence is indicated, it is to be understood that eachnumber is modified the same as the first number or last number in thenumerical sequence or in the sentence, e.g. each number is “at least,”or “up to” or “not more than” as the case may be; and each number is inan “or” relationship. For example, “at least 10, 20, 30, 40, 50, 75 wt.% . . . ” means the same as “at least 10 wt. %, or at least 20 wt. %, orat least 30 wt. %, or at least 40 wt. %, or at least 50 wt. %, or atleast 75 wt. %,” etc.; and “not more than 90 wt. %, 85, 70, 60 . . . ”means the same as “not more than 90 wt. %, or not more than 85 wt. %, ornot more than 70 wt. % . . . ” etc.; and “at least 1%, 2%, 3%, 4%, 5%,6%, 7%, 8%, 9% or 10% by weight . . . ” means the same as “at least 1wt. %, or at least 2 wt. %, or at least 3 wt. % . . . ” etc.; and “atleast 5, 10, 15, 20 and/or not more than 99, 95, 90 weight percent”means the same as “at least 5 wt. %, or at least 10 wt. %, or at least15 wt. % or at least 20 wt. % and/or not more than 99 wt. %, or not morethan 95 wt. %, or not more than 90 weight percent . . . ” etc.

All concentrations or amounts are by weight unless otherwise stated.

Overall Chemical Recycling Facility

Turning now to FIG. 1 , the main steps of a process for chemicallyrecycling waste plastic in a chemical recycling facility 10 are shown.It should be understood that FIG. 1 depicts one exemplary embodiment ofthe present technology. Certain features depicted in FIG. 1 may beomitted and/or additional features described elsewhere herein may beadded to the system depicted in FIG. 1 .

As shown in FIG. 1 , these steps generally include a pre-processingstep/facility 20, and at least one (or at least two or more) of asolvolysis step/facility 30, a partial oxidation (POX) gasificationstep/facility 50, a pyrolysis step/facility 60, a cracking step/facility70, and an energy recovery step/facility 80. Optionally, in anembodiment or in combination with any embodiment mentioned herein, thesesteps may also include one or more other steps, such as, direct sale oruse, landfilling, separation, and solidification, one or more of whichis represented in FIG. 1 by block 90. Although shown as including all ofthese steps or facilities, it should be understood that a chemicalrecycling process and facility according to one or more embodiments ofthe present technology can include at least two, three, four, five, orall of these steps/facilities in various combinations for the chemicalrecycling of plastic waste and, in particular, mixed plastic waste.Chemical recycling processes and facilities as described herein may beused to convert waste plastic to recycle content products or chemicalintermediates used to form a variety of end use materials. The wasteplastic fed to the chemical recycling facility/process can be mixedplastic waste (MPW), pre-sorted waste plastic, and/or pre-processedwaste plastic.

As used herein, the term “chemical recycling” refers to a waste plasticrecycling process that includes a step of chemically converting wasteplastic polymers into lower molecular weight polymers, oligomers,monomers, and/or non-polymeric molecules (e.g., hydrogen and carbonmonoxide) that are useful by themselves and/or are useful as feedstocksto another chemical production process or processes. A “chemicalrecycling facility,” is a facility for producing a recycle contentproduct via chemical recycling of waste plastic. As used herein, theterms “recycle content” and “r-content” mean being or comprising acomposition that is directly and/or indirectly derived from wasteplastic.

As used herein, the term “directly derived” ‘means having at least onephysical component originating from waste plastic, while “indirectlyderived” means having an assigned recycle content that i) isattributable to waste plastic, but ii) that is not based on having aphysical component originating from waste plastic.

Chemical recycling facilities are not mechanical recycling facilities.As used herein, the terms “mechanical recycling” and “physicalrecycling” refer to a recycling process that includes a step of meltingwaste plastic and forming the molten plastic into a new intermediateproduct (e.g., pellets or sheets) and/or a new end product (e.g.,bottles). Generally, mechanical recycling does not substantially changethe chemical structure of the plastic being recycled. In one embodimentor in combination with any of the mentioned embodiments, the chemicalrecycling facilities described herein may be configured to receive andprocess waste streams from and/or that are not typically processable bya mechanical recycling facility.

Although described herein as being part of a single chemical recyclingfacility, it should be understood that one or more of the preprocessingfacility 20, the solvolysis facility 30, the pyrolysis facility 60, thecracking facility 70, the partial oxidation (POX) gasification facility50, and the energy recovery facility 80, or any of the other facility 90such as solidification or separation, may be located in a differentgeographical location and/or be operated by a different commercialentity. Each of the preprocessing facility 20, the solvolysis facility30, the pyrolysis facility 60, the cracking facility 70, the partialoxidation (POX) gasification facility 50, the energy recovery facility80, or any other facility 90 s may be operated by the same entity,while, in other cases, one or more of the preprocessing facility 20, thesolvolysis facility 30, the pyrolysis facility 60, the cracking facility70, the partial oxidation (POX) gasification facility 50, asolidification facility, the energy recovery facility 80, and one ormore other facility 90 such as separation or solidification, may beoperated by a different commercial entity.

In an embodiment or in combination with any embodiment mentioned herein,the chemical recycling facility 10 may be a commercial-scale facilitycapable of processing significant volumes of mixed plastic waste. Asused herein, the term “commercial scale facility” refers to a facilityhaving an average annual feed rate of at least 500 pounds per hour,averaged over one year. The average feed rate to the chemical recyclingfacility (or to any one of the preprocessing facility 20, the solvolysisfacility 30, the pyrolysis facility 60, the cracking facility 70, thePOX gasification facility 50, the energy recovery facility 80, and anyother facility 90) can be at least 750, at least 1,000, at least 1,500,at least 2,000, at least 2,500, at least 3,000, at least 3,500, at least4,000, at least 4,500, at least 5,000, at least 5,500, at least 6,000,at least 6,500, at least 7,500, at least 10,000, at least 12,500, atleast 15,000, at least 17,500, at least 20,000, at least 22,500, atleast 25,000, at least 27,500, at least 30,000 or at least 32,500 poundsper hour and/or not more than 1,000,000, not more than 750,000, not morethan 500,000, not more than 450,000, not more than 400,000, not morethan 350,000, not more than 300,000, not more than 250,000, not morethan 200,000, not more than 150,000, not more than 100,000, not morethan 75,000, not more than 50,000, or not more than 40,000 pounds perhour. When a facility includes two or more feed streams, the averageannual feed rate is determined based on the combined weight of the feedstreams.

Additionally, it should be understood that each of the preprocessingfacility 20, the solvolysis facility 30, the pyrolysis facility 60, thecracking facility 70, the POX gasification facility 50, the energyrecovery facility 80, and any other facility 90 may include multipleunits operating in series or parallel. For example, the pyrolysisfacility 60 may include multiple pyrolysis reactors/units operating inparallel and each receiving a feed comprising waste plastic. When afacility is made up of multiple individual units, the average annualfeed rate to the facility is calculated as the sum of the average annualfeed rates to all of the common types of units within that facility.

Additionally, in an embodiment or in combination with any embodimentmentioned herein, the chemical recycling facility 10 (or any one of thepreprocessing facility 20, the solvolysis facility 30, the pyrolysisfacility 60, the cracking facility 70, the POX gasification facility 50,the energy recovery facility 80, and any other facility 90) may beoperated in a continuous manner. Additionally, or in the alternative, atleast a portion of the chemical recycling facility 10 (or any of thepreprocessing facility 20, the solvolysis facility 30, the pyrolysisfacility 60, the cracking facility 70, the POX gasification facility 50,the energy recovery facility 80, and any other facility 90) may beoperated in a batch or semi-batch manner. In some cases, the facilitymay include a plurality of tanks between portions of a single facilityor between two or more different facilities to manage inventory andensure consistent flow rates into each facility or portion thereof.

In addition, two or more of the facilities shown in FIG. 1 may also beco-located with one another. In an embodiment or in combination with anyembodiment mentioned herein, at least two, at least three, at leastfour, at least five, at least six, or all of the facilities may beco-located. As used herein, the term “co-located” refers to facilitiesin which at least a portion of the process streams and/or supportingequipment or services are shared between the two facilities. When two ormore of the facilities shown in FIG. 1 are co-located, the facilitiesmay meet at least one of the following criteria (i) through (v): (i) thefacilities share at least one non-residential utility service; (ii) thefacilities share at least one service group; (iii) the facilities areowned and/or operated by parties that share at least one propertyboundary; (iv) the facilities are connected by at least one conduitconfigured to carry at least one process material (e.g., solid, liquidand/or gas fed to, used by, or generated in a facility) from onefacility to another; and (v) the facilities are within 40, within 35,within 30, within 20, within 15, within 12, within 10, within 8, within5, within 2, or within 1 mile of one another, measured from theirgeographical center. At least one, at least two, at least three, atleast four, or all of the above statements (i) through (v) may be true.

Regarding (i), examples of suitable utility services include, but arenot limited to, steam systems (co-generation and distribution systems),cooling water systems, heat transfer fluid systems, plant or instrumentair systems, nitrogen systems, hydrogen systems, non-residentialelectrical generation and distribution, including distribution above8000V, non-residential wastewater/sewer systems, storage facilities,transport lines, flare systems, and combinations thereof.

Regarding (ii), examples of service groups and facilities include, butare not limited to, emergency services personnel (fire and/or medical),a third-party vendor, a state or local government oversight group, andcombinations thereof. Government oversight groups can include, forexample, regulatory or environmental agencies, as well as municipal andtaxation agencies at the city, county, and state level.

Regarding (iii), the boundary may be, for example, a fence line, aproperty line, a gate, or common boundaries with at least one boundaryof a third-party owned land or facility.

Regarding (iv), the conduit may be a fluid conduit that carries a gas, aliquid, a solid/liquid mixture (e.g., slurry), a solid/gas mixture(e.g., pneumatic conveyance), a solid/liquid/gas mixture, or a solid(e.g., belt conveyance). In some cases, two units may share one or moreconduits selected from the above list. Fluid conduits may be used totransport process streams or utilities between the two units. Forexample, an outlet of one facility (e.g., the solvolysis facility 30)may be fluidly connected via a conduit with an inlet of another facility(e.g., the POX gasification facility 50). In some cases, an interimstorage system for the materials being transported within the conduitbetween the outlet of one facility and the inlet of another facility maybe provided. The interim storage system may comprise, for example, oneor more tanks, vessels (open or closed), buildings, or containers thatare configured to store the material carried by the conduit. In somecases, the interim storage between the outlet of one facility and theinlet of another can be not more than 90, not more than 75, not morethan 60, not more than 40, not more than 30, not more than 25, not morethan 20, not more than 15, not more than 10, not more than 5, not morethan 2 days or not more than 1 day.

Waste Plastic

Turning again to FIG. 1 , a stream 100 of waste plastic, which can bemixed plastic waste (MPW), may be introduced into the chemical recyclingfacility 10. As used herein, the terms “waste plastic” and “plasticwaste” refer to used, scrap, and/or discarded plastic materials, such asplastic materials typically sent to a landfill. Other examples of wasteplastic (or plastic waste) include used, scrap, and/or discarded plasticmaterials typically sent to an incinerator. The waste plastic stream 100fed to the chemical recycling facility may include unprocessed orpartially processed waste plastic. As used herein, the term “unprocessedwaste plastic” means waste plastic that has not be subjected to anyautomated or mechanized sorting, washing, or comminuting. Examples ofunprocessed waste plastic include waste plastic collected from householdcurbside plastic recycling bins or shared community plastic recyclingcontainers. As used herein, the term “partially processed waste plastic”means waste plastic that has been subjected to at least one automated ormechanized sorting, washing, or comminuting step or process. Partiallyprocessed waste plastics may originate from, for example, municipalrecycling facilities (MRFs) or reclaimers. When partially processedwaste plastic is provided to the chemical recycling facility 10, one ormore preprocessing steps may be skipped. Waste plastic may comprise atleast one of post-industrial (or pre-consumer) plastic and/orpost-consumer plastic.

As used herein, the terms “mixed plastic waste” and “MPW” refer to amixture of at least two types of waste plastics including, but notlimited to the following plastic types: polyethylene terephthalate(PET), one or more polyolefins (PO), and polyvinylchloride (PVC). In anembodiment or in combination with any embodiment mentioned herein, MPWincludes at least two distinct types of plastic, with each type ofplastic being present in an amount of at least 1, at least 2, at least5, at least 10, at least 15, or at least 20 weight percent, based on thetotal weight of plastic in the MPW.

In an embodiment or in combination with any embodiment mentioned herein,MPW comprises at least 1, at least 2, at least 5, at least 10, at least15, at least 20, at least 25, at least 30, at least 35, at least 40, atleast 45, at least 50, at least 55, at least 60, at least 65, at least70, at least 75, at least 80, at least 85, at least 90, at least 95, orat least 99 weight percent PET and/or at least 1, at least 2, at least5, at least 10, at least 15, or at least 20 weight percent PO, based onthe total weight of plastic in the MPW. In one embodiment or moreembodiments, MPW may also include minor amounts of one or more types ofplastic components other than PET and PO (and optionally PVC) that totalless than 50, less than 45, less than 40, less than 35, less than 30,less than 25, less than 20, less than 15, less than 10, less than 5,less than 2, or less than 1 weight percent, based on the total weight ofplastic in the MPW.

In an embodiment or in combination with any embodiment mentioned herein,the MPW comprises at least 20, at least 25, at least 30, at least 35, atleast 40, at least 45, at least 50, at least 55, at least 60, at least65, at least 70, at least 75, at least 80, at least 85, at least 90, orat least 95 weight percent PET, based on the total weight of the stream.Alternatively, or in addition, the MPW comprises not more than 99.9, notmore than 99, not more than 97, not more than 92, not more than 90, notmore than 85, not more than 80, not more than 75, not more than 70, notmore than 65, not more than 60, not more than 55, not more than 50, notmore than 45, not more than 40, not more than 35, not more than 30, notmore than 25, not more than 20, not more than 15, not more than 10, ornot more than 5 weight percent PET, based on the total weight of thestream.

The MPW stream can include non-PET components in an amount of at least0.1, at least 0.5, at least 1, at least 2, at least 5, at least 7, atleast 10, at least 15, at least 20, at least 25, at least 30, or atleast 35 and/or not more than 80, not more than 75, not more than 70,not more than 65, not more than 60, not more than 55, not more than 50,not more than 45, not more than 40, not more than 35, not more than 30,not more than 25, not more than 20, not more than 15, not more than 10,or not more than 7 weight percent, based on the total weight of thestream. Non-PET components can be present in an amount between 0.1 and50 weight percent, 1 and 20 weight percent, or 2 and weight percent,based on the total weight of the stream. Examples of such non-PETcomponents can include, but are not limited to, ferrous and non-ferrousmetals, inerts (such as rocks, glass, sand, etc.), plastic inerts (suchas titanium dioxide, silicon dioxide, etc.), olefins, adhesives,compatibilizers, biosludge, cellulosic materials (such as cardboard,paper, etc.), and combinations thereof.

In an embodiment or in combination with any embodiment mentioned herein,all or a portion of the MPW can originate from a municipal source orcomprise municipal waste. The municipal waste portion of the MPW caninclude, for example, PET in an amount of from 45 to 95 weight percent,50 to 90 weight percent, or 55 to 85 weight percent, based on the totalweight of the municipal waste stream (or portion of the stream).

In an embodiment or in combination with any embodiment mentioned herein,all or a portion of the MPW can originate from a municipal recyclingfacility (MRF) and may include, for example, PET in an amount of from 65to 99.9 weight percent, 70 to 99 weight percent, or 80 to 97 weightpercent, based on the total weight of the stream. The non-PET componentsin such streams may include, for example, other plastics in an amount ofat least 1, at least 2, at least 5, at least 7, or at least 10 weightpercent and/or not more than 25, not more than 22, not more than 20, notmore than 15, not more than 12, or not more than 10 weight percent,based on the total weight of the stream, or such may be present in anamount in the range of from 1 to 22 weight percent, 2 to weight percent,or 5 to 12 weight percent, based on the total weight of the stream. Inan embodiment or in combination with any embodiment mentioned herein,the non-PET components can include other plastics in an amount in therange of from 2 to 35 weight percent, 5 to 30 weight percent, or 10 to25 weight percent, based on the total weight of the stream, particularlywhen, for example, the MPW includes colored sorted plastics.

In an embodiment or in combination with any embodiment mentioned herein,all or a portion of the MPW can originate from a reclaimer facility andmay include, for example, PET in an amount of from 85 to 99.9 weightpercent, 90 to 99.9 weight percent, or 95 to 99 weight percent, based onthe total weight of the stream. The non-PET components in such streamsmay include, for example, other plastics in an amount of at least 1, atleast 2, at least 5, at least 7, or at least 10 weight percent and/ornot more than 25, not more than 22, not more than 20, not more than 15,not more than 12, or not more than 10 weight percent, based on the totalweight of the stream, or such may be present in an amount in the rangeof from 1 to 22 weight percent, 2 to 15 weight percent, or to 12 weightpercent, based on the total weight of the stream.

As used herein, the term “plastic” may include any organic syntheticpolymers that are solid at 25° C. and 1 atmosphere of pressure. In anembodiment or in combination with any embodiment mentioned herein, thepolymers may have a number average molecular weight (Mn) of at least 75,or at least 100, or at least 125, or at least 150, or at least 300, orat least 500, or at least 1000, or at least 5,000, or at least 10,000,or at least 20,000, or at least 30,000, or at least 50,000 or at least70,000 or at least 90,000 or at least 100,000 or at least 130,000Daltons. The weight average molecular weight (Mw) of the polymers can beat least 300, or at least 500, or at least 1000, or at least 5,000, orat least 10,000, or at least 20,000, or at least 30,000 or at least50,000, or at least 70,000, or at least 90,000, or at least 100,000, orat least 130,000, or at least 150,000, or at least 300,000 Daltons.

Examples of suitable plastics can include, but are not limited to,aromatic and aliphatic polyesters, polyolefins, polyvinyl chloride(PVC), polystyrene, polytetrafluoroethylene, acrylobutadienestyrene(ABS), cellulosics, epoxides, polyamides, phenolic resins, polyacetal,polycarbonates, polyphenylene-based alloys, poly(methyl methacrylate),styrene-containing polymers, polyurethane, vinyl-based polymers, styreneacrylonitrile, thermoplastic elastomers other than tires, and ureacontaining polymers and melamines.

Examples of polyesters can include those having repeating aromatic orcyclic units such as those containing a repeating terephthalate,isophthalate, or naphthalate units such as PET, modified PET, and PEN,or those containing repeating furanate repeating units. Polyethyleneterephthalate (PET) is also an example of a suitable polyester. As usedherein, “PET” or “polyethylene terephthalate” refers to a homopolymer ofpolyethylene terephthalate, or to a polyethylene terephthalate modifiedwith one or more acid and/or glycol modifiers and/or containing residuesor moieties of other than ethylene glycol and terephthalic acid, such asisophthalic acid, 1,4-cyclohexanedicarboxylic acid, diethylene glycol,2,2,4,4-tetramethyl-1,3-cyclobutanediol (TMCD), cyclohexanedimethanol(CHDM), propylene glycol, isosorbide, 1,4-butanediol, 1,3-propane diol,and/or neopentyl glycol (NPG).

Also included within the definition of the terms “PET” and “polyethyleneterephthalate” are polyesters having repeating terephthalate units(whether or not they contain repeating ethylene glycol-based units) andone or more residues or moieties of a glycol including, for example,TMCD, CHDM, propylene glycol, or NPG, isosorbide, 1,4-butanediol,1,3-propane diol, and/or diethylene glycol, or combinations thereof.Examples of polymers with repeat terephthalate units can include, butare not limited to, polypropylene terephthalate, polybutyleneterephthalate, and copolyesters thereof. Examples of aliphaticpolyesters can include, but are not limited to, polylactic acid (PLA),polyglycolic acid, polycaprolactones, and polyethylene adipates. Thepolymer may comprise mixed aliphatic-aromatic copolyesters including,for example, mixed terephthalates/adipates.

In an embodiment or in combination with any embodiment mentioned herein,the waste plastic may comprise at least one type of plastic that hasrepeat terephthalate units with such a plastic being present in anamount of at least 1, at least 2, at least 5, at least 10, at least 15,at least 20, at least 25, or at least 30 and/or not more than 45, notmore than 40, not more than 35, not more than 30, not more than 25, notmore than 20, not more than 15, not more than 10, not more than 5, ornot more than 2 weight percent, based on the total weight of the stream,or it can be present in the range of from 1 to 45 weight percent, 2 to40 weight percent, or 5 to 40 weight percent, based on the total weightof the stream. Similar amounts of copolyesters having multiplecyclohexane dimethanol moieties, 2,2,4,4-tetramethyl-1,3-cyclobutanediolmoieties, or combinations thereof may also be present.

In an embodiment or in combination with any embodiment mentioned herein,the waste plastic may comprise at least one type of plastic that hasrepeat terephthalate units with such a plastic being present in anamount of at least 30, at least 35, at least 40, at least 45, at least50, at least 55, at least 60, at least 65, at least 70, at least 75, atleast 80, at least 85, or at least 90 and/or not more than 99.9, notmore than 99, not more than 97, not more than 95, not more than 90, ornot more than 85 weigh percent, based on the total weight of the stream,or it can be present in the range of from 30 to 99.9 weight percent, 50to 99.9 weight percent, or 75 to 99 weight percent, based on the totalweight of the stream.

In an embodiment of in combination with any embodiment mentioned herein,the waste plastic may comprise terephthalate repeat units in an amountof at least 1, at least 5, at least 10, at least 15, at least 20, atleast 25, at least 30, at least 35, at least 40, or at least 45 and/ornot more than 75, not more than 72, not more than 70, not more than 60,or not more than 65 weight percent, based on the total weight of theplastic in the waste plastic stream, or it may include terephthalaterepeat units in an amount in the range of from 1 to 75 weight percent, 5to 70 weight percent, or 25 to 75 weight percent, based on the totalweight of the stream.

Examples of specific polyolefins may include low density polyethylene(LDPE), high density polyethylene (HDPE), atactic polypropylene,isotactic polypropylene, syndiotactic polypropylene, crosslinkedpolyethylene, amorphous polyolefins, and the copolymers of any one ofthe aforementioned polyolefins. The waste plastic may include polymersincluding linear low-density polyethylene (LLDPE), polymethylpentene,polybutene-1, and copolymers thereof. The waste plastic may compriseflashspun high density polyethylene.

The waste plastic may include thermoplastic polymers, thermosettingpolymers, or combinations thereof. In an embodiment or in combinationwith any embodiment mentioned herein, the waste plastic can include atleast 0.1, at least 1, at least 2, at least 5, at least 10, at least 15,at least 20, at least 25, or at least 30 and/or not more than 45, notmore than 40, not more than 35, not more than 30, not more than 25, notmore than 20, not more than 15, not more than 10, not more than 5, ornot more than 2 weight percent of one or more thermosetting polymers,based on the total weight of the stream, or it can be present in anamount of 0.1 to 45 weight percent, 1 to weight percent, 2 to 35 weightpercent, or 2 to 20 weight percent, based on the total weight of thestream.

Alternatively, or in addition, the waste plastic may include at least0.1, at least 1, at least 2, at least 5, at least 10, at least 15, atleast 20, at least 25, or at least 30 and/or not more than 45, not morethan 40, not more than 35, not more than 30, not more than 25, not morethan 20, not more than 15, not more than 10, not more than 5, or notmore than 2 weight percent of cellulose materials, based on the totalweight of the stream, or it can be present in an amount in the range offrom 0.1 to 45 weight percent, 1 to 40 weight percent, or 2 to 15 weightpercent, based on the total weight of the stream. Examples of cellulosematerials may include cellulose acetate, cellulose diacetate, cellulosetriacetate, cellulose acetate propionate, cellulose acetate butyrate, aswell as regenerated cellulose such as viscose. Additionally, thecellulose materials can include cellulose derivatives having an acyldegree of substitution of less than 3, not more than 2.9, not more than2.8, not more than 2.7, or not more than 2.6 and/or at least 1.7, atleast 1.8, or at least 1.9, or from 1.8 to 2.8, or 1.7 to 2.9, or 1.9 to2.9.

In an embodiment or in combination with any embodiment mentioned herein,the waste plastic may comprise STYROFOAM or expanded polystyrene.

The waste plastic may originate from one or more of several sources. Inan embodiment or in combination with any embodiment mentioned herein,the waste plastic may originate from plastic bottles, diapers, eyeglassframes, films, packaging materials, carpet (residential, commercial,and/or automotive), textiles (clothing and other fabrics) andcombinations thereof.

In an embodiment or in combination with any embodiment mentioned herein,the waste plastic (e.g., MPW) fed to the chemical recycling facility mayinclude one or more plastics having or obtained from plastics having aresin ID code numbered 1-7 with the chasing arrow triangle establishedby the SPI. The waste plastic may include one or more plastics that arenot generally mechanically recycled. Such plastics can include, but arenot limited to, plastics with the resin ID code 3 (polyvinyl chloride),resin ID code 5 (polypropylene), resin ID code 6 (polystyrene), and/orresin ID code 7 (other). In an embodiment or in combination with anyembodiment mentioned herein, plastics having at least 1, at least 2, atleast 3, at least 4, or at least 5 of the resin ID codes 3-7 or 3, 5, 6,7, or a combination thereof may be present in the waste plastic in anamount of at least 0.1, at least 0.5, at least 1, at least 2, at least3, at least 5, at least 7, at least 10, at least 12, at least 15, atleast 20, at least 25, at least 30, at least 35, or at least 40 and/ornot more than 90, not more than 85, not more than 80, not more than 75,not more than 70, not more than 65, not more than 60, not more than 55,not more than 50, not more than 45, not more than 40, or not more than35 weight percent, based on the total weight of all plastics, or itcould be in an amount of 0.1 to 90 weight percent, 1 to 75 weightpercent, or 2 to 50 weight percent, based on the total weight ofplastics.

In an embodiment or in combination with any embodiment mentioned herein,at least 5, at least 10, at least 15, at least 20, at least 25, at least30, or at least 35 and/or not more than 60, not more than 55, not morethan 50, not more than 45, not more than 40, not more than 35, not morethan 30, not more than 25, not more than 20, not more than 15, not morethan 10, or not more than 5 weight percent of the total plasticcomponents in the waste plastic fed to the chemical recycling facilitymay comprise plastics not having a resin ID code 3, 5, 6, and/or 7(e.g., where a plastic is not classified). At least 0.1, at least 0.5,at least 1, at least 2, at least 3, at least 4, at least 5, at least 10,at least 15, at least 20, at least 25, at least 30, or at least 35and/or not more than 60, not more than 55, not more than 50, not morethan 45, not more than 40, not more than 35, not more than 30, not morethan 25, not more than 20, not more than 15, not more than 10, or notmore than 5 weight percent of the total plastic components in the wasteplastic fed to the chemical recycling facility 10 may comprise plasticsnot having a resin ID code 4-7, or it can be in the range of 0.1 to 60weight percent, 1 to 55 weight percent, or 2 to 45 weight percent, basedon the total weight of plastic components.

In an embodiment or in combination with any embodiment mentioned herein,the waste plastic (e.g., MPW) fed to the chemical recycling facility maycomprise plastic that is not classified as resin ID codes 3-7 or IDcodes 3, 5, 6, or 7. The total amount of plastic not classified as resinID code 3-7 or ID codes 3, 5, 6, or 7 plastics in the waste plastic canbe at least 0.1, at least 0.5, at least 1, at least 2, at least 3, atleast 4, at least 5, at least 10, at least 15, at least 20, at least 25,at least 30, at least 35, at least 40, at least 45, at least 50, atleast 55, at least 60, at least 65, at least 70, or at least 75 and/ornot more than 95, not more than 90, not more than 85, not more than 80,not more than 75, not more than 70, not more than 65, not more than 60,not more than 55, not more than 50, not more than 45, not more than 40,or not more than 35 weight percent, based on the total weight of plasticin the waste plastic stream, or it can be in the range of from 0.1 to 95weight percent, 0.5 to 90 weight percent, or 1 to 80 weight percent,based on the total weight of plastic in the waste plastic stream.

In one embodiment or in combination with any of the mentionedembodiments, the MPW comprises plastics having or obtained from plasticshaving at least 30, at least 35, at least 40, at least 45, at least 50,at least 55, at least 60, at least 65, at least 70, at least 75, atleast 80, at least 85, at least 90, at least 95, or at least 99 weightpercent of at least one, at least two, at least three, or at least fourdifferent kinds of resin ID codes.

In one embodiment or in combination with any of the mentionedembodiments, the MPW comprises multi-component polymers. As used herein,the term “multi-component polymers” refers to articles and/orparticulates comprising at least one synthetic or natural polymercombined with, attached to, or otherwise physically and/or chemicallyassociated with at least one other polymer and/or non-polymer solid. Thepolymer can be a synthetic polymer or plastic, such as PET, olefins,and/or nylons. The non-polymer solid can be a metal, such as aluminum,or other non-plastic solids as described herein. The multi-componentpolymers can include metalized plastics.

In one embodiment or in combination with any of the mentionedembodiments, the MPW comprises multi-component plastics in the form ofmulti-layer polymers. As used herein, the term “multi-layer polymers”refers to multi-component polymers comprising PET and at least one otherpolymer and/or non-polymer solid physically and/or chemically associatedtogether in two or more physically distinct layers. A polymer or plasticis considered a multi-layered polymer even though a transition zone mayexist between two layers, such as may be present in adhesively adheredlayers or co-extruded layers. An adhesive between two layers is notdeemed to be a layer. The multi-layer polymers may comprise a layercomprising PET and a one or more additional layers at least one of whichis a synthetic or natural polymer that is different from PET, or apolymer which has no ethylene terephthalate repeating units, or apolymer which has no alkylene terephthalate repeating units (a “non-PETpolymer layer”), or other non-polymer solid.

Examples of non-PET polymer layers include nylons, polylactic acid,polyolefins, polycarbonates, ethylene vinyl alcohol, polyvinyl alcohol,and/or other plastics or plastic films associated with PET-containingarticles and/or particulates, and natural polymers such as wheyproteins. The multi-layer polymers may include metal layers, such asaluminum, provided that at least one additional polymer layer is presentother than the PET layer. The layers may be adhered with adhesivebonding or other means, physically adjacent (i.e., articles pressedagainst the film), tackified (i.e., the plastics heated and stucktogether), co-extruded plastic films, or otherwise attached to thePET-containing articles. The multi-layer polymers may comprise PET filmsassociated with articles containing other plastics in the same orsimilar manner. The MPW may comprise multi-component polymers in theform of PET and at least one other plastic, such as polyolefins (e.g.,polypropylene) and/or other synthetic or natural polymers, combined in asingle physical phase. For example, the MPW comprises a heterogenousmixture comprising a compatibilizer, PET, and at least one othersynthetic or natural polymer plastic (e.g., non-PET plastic) combined ina single physical phase. As used herein, the term “compatibilizer”refers to an agent capable of combining at least two otherwiseimmiscible polymers together in a physical mixture (i.e., blend).

In one embodiment or in combination with any of the mentionedembodiments, the MPW comprises not more than 20, not more than 10, notmore than 5, not more than 2, not more than 1, or not more than 0.1weight percent nylons, on a dry plastic basis. In one embodiment or incombination with any of the mentioned embodiments, the MPW comprisesfrom 0.01 to 20, from 0.05 to 10, from 0.1 to 5, or from 1 to 2 weightpercent nylons, on a dry plastic basis.

In one embodiment or in combination with any of the mentionedembodiments, the MPW comprises not more than 40, not more than 20, notmore than 10, not more than 5, not more than 2, or not more than 1weight percent multi-component plastics, on a dry plastic basis. In oneembodiment or in combination with any of the mentioned embodiments, theMPW comprises from 0.1 to 40, from 1 to 20, or from 2 to 10 weightpercent multi-component plastics, on a dry plastic basis. In oneembodiment or in combination with any of the mentioned embodiments, theMPW comprises not more than 40, not more than 20, not more than 10, notmore than 5, not more than 2, or not more than 1 weight percentmulti-layer plastics, on a dry plastic basis. In one embodiment or incombination with any of the mentioned embodiments, the MPW comprisesfrom 0.1 to 40, from 1 to 20, or from 2 to 10 weight percent multi-layerplastics, on a dry plastic basis.

In one embodiment or in combination with any of the mentionedembodiments, the MPW feedstock to the chemical recycling facility 10 instream 100 comprises not more than 20, not more than 15, not more than12, not more than 10, not more than 8, not more than 6, not more than 5,not more than 4, not more than 3, not more than 2, or not more than 1weight percent of biowaste materials, with the total weight of the MPWfeedstock taken as 100 weight percent on a dry basis. The MPW feedstockcomprises from 0.01 to 20, from 0.1 to 10, from 0.2 to 5, or from 0.5 to1 weight percent of biowaste materials, with the total weight of the MPWfeedstock taken as 100 weight percent on a dry basis. As used herein,the term “biowaste” refers to material derived from living organisms orof organic origin. Exemplary biowaste materials include, but are notlimited to, cotton, wood, saw dust, food scraps, animals and animalparts, plants and plant parts, and manure.

In one embodiment or in combination with any of the mentionedembodiments, the MPW feedstock comprises not more than 20, not more than15, not more than 12, not more than 10, not more than 8, not more than6, not more than 5, not more than 4, not more than 3, not more than 2,or not more than 1 weight percent of manufactured cellulose products,with the total weight of the MPW feedstock taken as 100 weight percenton a dry basis. The MPW feedstock comprises from 0.01 to 20, from 0.1 to10, from 0.2 to 5, or from 0.5 to 1 weight percent of manufacturedcellulose products, with the total weight of the MPW feedstock taken as100 weight percent on a dry basis. As used herein, the term“manufactured cellulose products” refers to nonnatural (i.e., manmade ormachine-made) articles, and scraps thereof, comprising cellulosicfibers. Exemplary manufactured cellulose products include, but are notlimited to, paper and cardboard.

In an embodiment or in combination with any embodiment mentioned herein,the waste plastic (e.g., MPW) fed to the chemical recycling facility caninclude at least 0.001, at least 0.01, at least 0.05, at least 0.1, orat least 0.25 weight percent and/or not more than 10, not more than 5,not more than 4, not more than 3, not more than 2, not more than 1, notmore than 0.75, or not more than 0.5 weight percent of polyvinylchloride (PVC) based on the total weight of plastics in the wasteplastic feed.

Additionally, or in the alternative, the waste plastic (e.g., MPW) fedto the chemical recycling facility can include at least 0.1, at least 1,at least 2, at least 4, or at least 6 weight percent and/or not morethan 25, not more than 15, not more than 10, not more than 5, or notmore than 2.5 weight percent of non-plastic solids. Non-plastic solidsmay include inert filler materials (e.g., calcium carbonate, hydrousaluminum silicate, alumina trihydrate, calcium sulfate), rocks, glass,and/or additives (e.g., thixotropes, pigments and colorants, fireretardants, suppressants, UV inhibitors & stabilizers, conductive metalor carbon, release agents such as zinc stearate, waxes, and silicones).

In one embodiment or in combination with any of the mentionedembodiments, the MPW may comprise at least 0.01, at least 0.1, at least0.5, or at least 1 and/or not more than 25, not more than 20, not morethan 25, not more than 10, not more than 5, or not more than 2.5 weightpercent of liquids, based on the total weight of the MPW stream orcomposition. The amount of liquids in the MPW can be in the range offrom 0.01 to 25 weight percent, from 0.5 to 10 weight percent, or 1 to 5weight percent, based on the total weight of the MPW stream 100.

In one embodiment or in combination with any of the mentionedembodiments, the MPW may comprise at least 35, at least 40, at least 45,at least 50, or at least 55 and/or not more than 65, not more than 60,not more than 55, not more than 50, not more than 45, not more than 40,or not more than 35 weight percent of liquids, based on the total weightof the waste plastic. The liquids in the waste plastic can be in therange of from 35 to 65 weight percent, 40 to 60 weight percent, or 45 to55 weight percent, based on the total weight of the waste plastic.

In one embodiment or in combination with any of the mentionedembodiments, the amount of textiles (including textile fibers) in theMPW stream in line 100 can be at least 0.1 weight percent, or at least0.5 weight percent, or at least 1 weight percent, or at least 2 weightpercent, or at least 5 weight percent, or at least 8 weight percent, orat least 10 weight percent, or at least weight percent, or at least 20weight percent material obtained from textiles or textile fibers, basedon the weight of the MPW. The amount of textiles (including textilefibers) in the MPW in stream 100 is not more than 50, not more than 40,not more than 30, not more than 20, not more than 15, not more than 10,not more than 8, not more than 5, not more than 2, not more than 1, notmore than 0.5, not more than 0.1, not more than 0.05, not more than0.01, or not more than 0.001 weight percent, based on the weight of theMPW stream 100. The amount of textiles in the MPW stream 100 can be inthe range of from 0.1 to 50 weight percent, 5 to 40 weight percent, or10 to 30 weight percent, based on the total weight of the MPW stream100.

The MPW introduced into the chemical recycling facility 10 may containrecycle textiles. Textiles may contain natural and/or synthetic fibers,rovings, yarns, nonwoven webs, cloth, fabrics and products made from orcontaining any of the aforementioned items. Textiles can be woven,knitted, knotted, stitched, tufted, may include pressed fibers such asin felting, embroidered, laced, crocheted, braided, or may includenonwoven webs and materials. Textiles can include fabrics, and fibersseparated from a textile or other product containing fibers, scrap oroff-spec fibers or yarns or fabrics, or any other source of loose fibersand yarns. A textile can also include staple fibers, continuous fibers,threads, tow bands, twisted and/or spun yarns, gray fabrics made fromyarns, finished fabrics produced by wet processing gray fabrics, andgarments made from the finished fabrics or any other fabrics. Textilesinclude apparels, interior furnishings, and industrial types oftextiles. Textiles can include post-industrial textiles (pre-consumer)or post-consumer textiles or both.

In one embodiment or in combination with any of the mentionedembodiments, textiles can include apparel, which can generally bedefined as things humans wear or made for the body. Such textiles caninclude sports coats, suits, trousers and casual or work pants, shirts,socks, sportswear, dresses, intimate apparel, outerwear such as rainjackets, cold temperature jackets and coats, sweaters, protectiveclothing, uniforms, and accessories such as scarves, hats, and gloves.Examples of textiles in the interior furnishing category includefurniture upholstery and slipcovers, carpets and rugs, curtains, beddingsuch as sheets, pillow covers, duvets, comforters, mattress covers;linens, tablecloths, towels, washcloths, and blankets. Examples ofindustrial textiles include transportation (auto, airplane, train, bus)seats, floor mats, trunk liners, and headliners; outdoor furniture andcushions, tents, backpacks, luggage, ropes, conveyor belts, calendarroll felts, polishing cloths, rags, soil erosion fabrics andgeotextiles, agricultural mats and screens, personal protectiveequipment, bullet proof vests, medical bandages, sutures, tapes, and thelike.

The nonwoven webs that are classified as textiles do not include thecategory of wet laid nonwoven webs and articles made therefrom. While avariety of articles having the same function can be made from a dry orwet laid process, an article made from a dry laid nonwoven web isclassified as a textile. Examples of suitable articles that may beformed from dry laid nonwoven webs as described herein can include thosefor personal, consumer, industrial, food service, medical, and other enduses. Specific examples can include, but are not limited to, baby wipes,flushable wipes, disposable diapers, training pants, feminine hygieneproducts such as sanitary napkins and tampons, adult incontinence pads,underwear, or briefs, and pet training pads. Other examples include avariety of different dry or wet wipes, including those for consumer(such as personal care or household) and industrial (such as foodservice, health care, or specialty) use. Nonwoven webs can also be usedas padding for pillows, mattresses, and upholstery, and batting forquilts and comforters. In the medical and industrial fields, nonwovenwebs of the present invention may be used for consumer, medical, andindustrial face masks, protective clothing, caps, and shoe covers,disposable sheets, surgical gowns, drapes, bandages, and medicaldressings.

Additionally, nonwoven webs as described herein may be used forenvironmental fabrics such as geotextiles and tarps, oil and chemicalabsorbent pads, as well as building materials such as acoustic orthermal insulation, tents, lumber and soil covers and sheeting. Nonwovenwebs may also be used for other consumer end use applications, such asfor, carpet backing, packaging for consumer, industrial, andagricultural goods, thermal or acoustic insulation, and in various typesof apparel.

The dry laid nonwoven webs as described herein may also be used for avariety of filtration applications, including transportation (e.g.,automotive or aeronautical), commercial, residential, industrial, orother specialty applications. Examples can include filter elements forconsumer or industrial air or liquid filters (e.g., gasoline, oil,water), including nanofiber webs used for microfiltration, as well asend uses like tea bags, coffee filters, and dryer sheets. Further,nonwoven webs as described herein may be used to form a variety ofcomponents for use in automobiles, including, but not limited to, brakepads, trunk liners, carpet tufting, and under padding.

The textiles can include single type or multiple type of natural fibersand/or single type or multiple type of synthetic fibers. Examples oftextile fiber combinations include all natural, all synthetic, two ormore type of natural fibers, two or more types of synthetic fibers, onetype of natural fiber and one type of synthetic fiber, one type ofnatural fibers and two or more types of synthetic fibers, two or moretypes of natural fibers and one type of synthetic fibers, and two ormore types of natural fibers and two or more types of synthetic fibers.

Natural fibers include those that are plant derived or animal derived.Natural fibers can be cellulosics, hemicellulosics, and lignins.Examples of plant derived natural fibers include hardwood pulp, softwoodpulp, and wood flour; and other plant fibers including those in wheatstraw, rice straw, abaca, coir, cotton, flax, hemp, jute, bagasse,kapok, papyrus, ramie, rattan, vine, kenaf, abaca, henequen, sisal, soy,cereal straw, bamboo, reeds, esparto grass, bagasse, Sabai grass,milkweed floss fibers, pineapple leaf fibers, switch grass,lignin-containing plants, and the like. Examples of animal derivedfibers include wool, silk, mohair, cashmere, goat hair, horsehair, avianfibers, camel hair, angora wool, and alpaca wool.

Synthetic fibers are those fibers that are, at least in part,synthesized or derivatized through chemical reactions, or regenerated,and include, but are not limited to, rayon, viscose, mercerized fibersor other types of regenerated cellulose (conversion of natural celluloseto a soluble cellulosic derivative and subsequent regeneration) such aslyocell (also known as TENCEL™), Cupro, Modal, acetates such aspolyvinyl acetate, polyamides including nylon, polyesters such as PET,olefinic polymers such as polypropylene and polyethylene,polycarbonates, poly sulfates, poly sulfones, polyethers such aspolyether-urea known as Spandex or elastane, polyacrylates,acrylonitrile copolymers, polyvinylchloride (PVC), polylactic acid,polyglycolic acid, sulfopolyester fibers, and combinations thereof.

Prior to entering the chemical recycling facility, the textiles can besize reduced via chopping, shredding, harrowing, confrication,pulverizing, or cutting to make size reduced textiles. The textiles canalso be densified (e.g., pelletized) prior to entering the chemicalrecycling facility. Examples of processes that densify include extrusion(e.g., into pellets), molding (e.g., into briquettes), and agglomerating(e.g., through externally applied heat, heat generated by frictionalforces, or by adding one or more adherents, which can be non-virginpolymers themselves). Alternatively, or in addition, the textiles can bein any of the forms mentioned herein and may be exposed to one or moreof the previously mentioned steps in the pre-processing facility 20prior to being processed in the remaining facilities of the chemicalrecycling facility 10 shown in FIG. 1 .

In an embodiment or in combination with any embodiment mentioned herein,polyethylene terephthalate (PET) and one or more polyolefins (PO) incombination make up at least 50, at least 55, at least 60, at least 65,at least 70, at least 75, at least 80, at least 85, at least 90, atleast 95, or at least 99 weight percent of the waste plastic (e.g., MPW)fed to the chemical recycling facility in stream 100 of FIG. 1 .Polyvinylchloride (PVC) can make up at least 0.001, at least 0.01, atleast 0.05, at least 0.1, at least 0.25, or at least 0.5 weight percentand/or not more than 10, not more than 5, not more than 4, not more than3, not more than 2, not more than 1, not more than 0.75, or not morethan 0.5 weight percent of the waste plastic, based on the total weightof the plastic in the waste plastic introduced into the chemicalrecycling facility 10.

In an embodiment or in combination with any embodiment mentioned herein,the waste plastic can comprise at least 5, at least 10, at least 15, atleast 20, at least 25, at least 30, at least 35, at least 40, at least45, at least 50, at least 55, at least 60, at least 65, at least 70, atleast 75, at least 80, at least 85, at least 90, or at least 95 weightpercent of PET, based on the total weight of the plastic in the wasteplastic introduced into the chemical recycling facility 10.

In an embodiment or in combination with any embodiment mentioned herein,the waste plastic can comprise at least 5, at least 10, at least 15, atleast 20, at least 25, at least 30, at least 35, at least 40 and/or notmore than 95, not more than 90, not more than 85, not more than 80, notmore than 75, not more than 70, not more than 65, not more than 60, notmore than 55, not more than 50, not more than 45, not more than 40, ornot more than 35 weight percent PO, based on the total weight of theplastic in the waste plastic, or PO can be present in an amount in therange of from 5 to 75 weight percent, 10 to 60 weight percent, or 20 to35 weight percent, based on the total weight of plastic in the wasteplastic introduced into the chemical recycling facility 10.

Waste Plastic Sources

In an embodiment or in combination with any embodiment mentioned herein,the waste plastic (e.g., MPW) introduced into the chemical recyclingfacility may be provided from a variety of sources, including, but notlimited to, municipal recycling facilities (MRFs) or reclaimerfacilities or other mechanical or chemical sorting or separationfacilities, manufacturers or mills or commercial production facilitiesor retailers or dealers or wholesalers in possession of post-industrialand pre-consumer recyclables, directly from households/businesses (i.e.,unprocessed recyclables), landfills, collection centers, conveniencecenters, or on docks or ships or warehouses thereon. In an embodiment orin combination with any embodiment mentioned herein, the source of wasteplastic (e.g. MPW) does not include deposit state return facilities,whereby consumers can deposit specific recyclable articles (e.g.,plastic containers, bottles, etc.) to receive a monetary refund from thestate. However, in an embodiment or in combination with any embodimentmentioned herein, the source of waste plastic (e.g. MPW) can includedeposit state return facilities, whereby consumers can deposit specificrecyclable articles (e.g., plastic containers, bottles, etc.) to receivea monetary refund from the state. Such return facilities are commonlyfound, for example, in grocery stores.

In an embodiment or in combination with any embodiment mentioned herein,the waste plastic may be provided as a waste stream from anotherprocessing facility, for example a municipal recycling facility (MRF) orreclaimer facility, or as a plastic-containing mixture comprising wasteplastic sorted by a consumer and left for collection at a curbside, orat a central convenience station. In one or more of such embodiments,the waste plastic comprises one or more MRF products or co-products,reclaimer co-products, sorted plastic-containing mixtures, and/orPET-containing waste plastic from a plastic article manufacturingfacility comprising at least 10, at least 20, at least 30, at least 40,at least 50, at least 60, at least 70, at least 80, or at least 90weight percent PET and/or not more than 99.9, not more than 99, not morethan 98, not more than 97, not more than 96, or not more than 95 weightpercent PET, on a dry plastics basis, or it can be in the range of from10 to 99.9 weight percent, 20 to 99 weight percent, 30 to 95 weightpercent, or 40 to 90 weight percent PET, on a dry plastics basis. In oneor more of such embodiments, the waste plastic comprises a quantity of aPET-containing reclaimer coproduct or plastic-containing mixturecomprising at least 1, at least 10, at least 30, at least 50, at least60, at least 70, at least 80, or at least 90 weight percent and/or notmore than 99.9, not more than 99, or not more than 90 weight percentPET, on a dry plastic basis, or it can be in the range of from 1 to 99.9weight percent, 1 to 99 weight percent, or 10 to 90 weight percent PET,on a dry plastic basis.

As noted above, exemplary sources of plastic waste introduced to thechemical recycling facility may include PET-containing reclaimerco-products (e.g., from a PET reclaimer facility), PET-containingmunicipal recycling facility (MRF) products or co-products, sortedplastic-containing mixtures, and/or PET-containing waste plastic from aplastic article manufacturing facility. Thus, in an embodiment or incombination with any embodiment mentioned herein, the present technologyis directed to methods of recycling plastic waste comprising feeding atleast a portion of one or more PET-containing materials includingreclaimer co-products, PET-containing MRF products or co-products,sorted plastic-containing mixtures, and/or PET-containing waste plasticfrom a plastic article manufacturing facility to a chemical recyclingfacility, wherein at least a portion of the co-products can be used asfeedstocks for chemical recycling processes, such as depolymerization,as described in greater detail below. The chemical recycling facilitymay comprise a solvolysis facility, including but not limited to analcoholysis facility, a methanolysis facility, a glycolysis facility,and/or a hydrolysis facility.

The one or more PET-containing materials may be fed directly to asolvolysis facility within said chemical recycling facility or may besubject to one or more preprocessing steps before being fed to thesolvolysis facility. For example, as shown in FIG. 1 , a plastic wastestream 100 from one or more plastic waste sources may be introduced to apre-processing facility 20 within chemical recycling facility 10, whichmay be configured to produce a PET-enriched stream 112 and aPET-depleted stream 114. The PET-enriched stream 112 from pre-processingfacility 20 may be introduced to solvolysis facility 30. Additionally,or alternatively, a plastic waste stream 100 a from one or more plasticwaste sources may be introduced directly to the solvolysis facility 30(i.e., without being introduced to pre-processing facility 20). Whethersubjected to pre-processing or fed directly, a quantity ofPET-containing materials from the one or more of waste plastic sourcesis ultimately fed to the solvolysis facility 30.

In an embodiment or in combination with any embodiment mentioned herein,at least a portion of the one or more PET-containing materials are feddirectly to a dissolver within the solvolysis facility 30, wherein theone or more PET-containing materials are mixed with solvent 212 and atleast partially liquified (see FIG. 3 ). In one or more suchembodiments, and particularly when fed directly to the dissolver, atleast a portion of the one or more PET containing materials may compriseless than 10, 8, 6, 5, 4, 2, or 1 weight percent nylon, polycarbonate,crosslinking agents (e.g., TMA), carpet glue, high filler contentmaterials, acetates, spandex, latex, styrene butadiene rubber,non-reactive materials (i.e., materials that do not react in thesolvolysis reactor, or that do not react to a degree so as to form asubstantial reaction product) including non-reactive metal oxides (suchas titanium dioxide, silicon dioxide, and alumina), calcium carbonate,talc, silica, glass, glass beads, reactive metal oxides (which maymethylate or glycolate in the reactor), and/or materials that formazeotropes with water, methanol, and/or ethylene glycol. A causticcomponent, such as a hydroxide solution or other caustic solution asdefined herein, may be added to the solvolysis facility, for example tothe solvolysis reactor and/or solvolysis reactor exit.

In an embodiment or in combination with any embodiment mentioned herein,at least a portion of the one or more PET-containing materials may beliquified, for example by melting and/or one or more other liquificationprocesses described herein, and fed subsequently fed to a reaction 210within the solvolysis facility 30 (see FIG. 3 ). In such embodiments, atleast a portion of the one or more PET-containing materials may be fedto a melt extruder, which is used as the feed system to the solvolysisfacility reactor.

In an embodiment or in combination with any embodiment mentioned herein,the one or more PET-containing materials described above may be the onlyplastic-containing feedstock for the solvolysis facility 30 (i.e., noPET-enriched stream 112 from the preprocessing facility 20 describedherein is fed with the one or more PET-containing materials to thesolvolysis facility 30). However, in an embodiment or in combinationwith any embodiment mentioned herein, the one or more PET-containingmaterials may be fed along with one or more other plastic-containingfeedstocks (e.g. the PET-enriched stream 112 from the preprocessingfacility 20 described herein) to the solvolysis facility 30. The one ormore PET-containing materials may comprise at least 5, at least 10, atleast 20, at least 40, at least 60, at least 80, or at least 90 weightpercent of the plastic-containing feedstock to the solvolysis facility30.

As described above, the one or more PET-containing materials may besubject to one or more preprocessing steps before being fed to thesolvolysis facility 30. The preprocessing steps may include feeding theone or more PET-containing materials to the preprocessing facility 20described herein and/or may include performing one or more of theprocesses described in the Preprocessing section herein. In one or moreembodiments, the preprocessing comprises any one or more of thefollowing: (i) separating at least a portion of the PET from thePET-containing materials using one or more density separation processes(e.g., sink-float or centrifugal force); and/or (ii) drying thePET-containing materials; and/or (iii) densifying (such as pelletizing)at least a portion of the PET-containing materials.

The one or more PET-containing materials may be provided to the chemicalrecycling facility 10 in a variety of transport methods and in a varietyof forms. For example, in an embodiment or in combination with anyembodiment mentioned herein, the PET-containing materials may betransported to the chemical recycling facility by truck, railroad,and/or conveyance in the form of whole articles, particulates, boundbales, unbound articles, containers, and/or piles. For example, thePET-containing materials can be provided to the chemical recyclingfacility 10 directly from a reclaimer facility and/or MRF facility usinga conveyance system interconnecting the chemical recycling facility 10to the reclaimer and/or municipal recycling facility.

The compositions of the one or more PET-containing materials will varydepending on the particular source of the materials, as described ingreater detail below. However, in an embodiment or in combination withany embodiment mentioned herein, the portion of PET-containing materialmay comprise at least 10, at least 20, at least 40, at least 60, atleast 80, or at least 90 weight percent PET on a dry basis. The portionof PET-containing material may comprise not more than 10, not more than8, not more than 6, not more than 4, not more than 2, or not more than 1weight percent halogens on a dry basis. The portion of PET-containingmaterial may comprise not more than 90, not more than 80, not more than70, not more than 60, not more than 50, not more than 40, not more than30, not more than 20, not more than 10, not more than 5, or not morethan 1 weight percent polyolefins on a dry basis.

Sorted Plastic-Containing Mixtures

As more municipalities are encouraging or mandating recycling of variousmaterials, including plastics, there is a growing supply ofPET-containing sorted plastic-containing mixtures. As used herein, theterm “sorted plastic-containing mixture” refers to a quantity of mixedplastic waste sorted by a consumer and left for collection at a curbsideor at a central convenience station, and may comprise clear and/orcolored plastic articles, or sorted by a trash collector ormunicipality. In an embodiment or in combination with any embodimentmentioned herein, the sorted plastic-containing mixtures does notinclude waste plastic from deposit state return facilities, as describedabove. However, in an embodiment or in combination with any embodimentmentioned herein, the sorted plastic-containing mixture may includewaste plastic from deposit state return facilities. The sortedplastic-containing mixture typically requires further processing and/orpurification before the plastic materials are useable for mechanicalrecycling processes, although this need not always be the case.

PET-Containing MRF Products and/or Co-Products

The sorted plastic-containing mixture may be collected by sanitationproviders and taken to a municipal recycling facility (also known as amaterials recovery facility or MRF) in which at least some attempt ismade to sort the mixture into quantities of like materials. Often, atleast some initial aspects of this sorting are performed manually. Inother aspects, machines including optical sorters, magnetic sorters, andeddy current sorters are used to conduct a more refined culling of thevarious materials present in the plastic-containing mixture. Forexample, colored plastics can be separated from clear plastics.Generally, “clear plastics” are considered to be plastics that appear tohave no color to the casual human observer and are generally transparentto light in the visible spectrum. “Colored plastic” is generallyconsidered to be any plastic that is not clear plastic. Glass, paper,and metals can also be separated from the plastics.

PET-containing plastics can be separated from other types of plastic toform a quantity of PET-enriched plastic material. The other separatedmaterials mentioned above and/or any other material from the MRF (i.e.,other than the PET-enriched product) may be recovered as MRF co-product.However, one or more of the MRF co-products will generally comprise someamount of PET. The MRF products and/or co-products may be in the form ofwhole articles, particulates (e.g., comminuted, pelletized, fiberplastic particulates), bound bales (e.g., whole articles compressed andstrapped), unbound articles (i.e., not in bales or packaged), containers(e.g., box, sack, trailer, railroad car, loader bucket), piles (e.g., ona concrete slab in a building), and/or loose materials conveyedphysically (e.g., particulates on a conveyor belt) or pneumatically(e.g., particulates mixed with air in a convey pipe).

PET-Containing Reclaimer Co-Products

Reclaimer facilities, and in particular PET reclaimers, generallyoperate by receiving plastic waste, for example from a MRF, andproducing r-PET comprising at least 99 or at least 99.9 percent byweight PET, which is used by mechanical recycling facilities to creater-PET products. The reclaimer facilities produce the r-PET by subjectingthe plastic waste to a variety of processes that separate PET fromnon-plastic components and plastic materials other than PET. However,these separation processes are usually less than 100% efficient andtypically result in some amount of PET being present in the co-products.The reclaimer facilities may also include processes that produce highpurity PET (at least 99 or at least 99.9 weight percent) reclaimerco-products but in a form that is undesirable to mechanical recyclingfacilities. As used herein, the term “reclaimer co-product” refers toany material separated or recovered by the reclaimer facility that isnot recovered as a clear rPET product, including colored rPET. Thereclaimer co-products described above and below are generally consideredto be waste products and may typically be sent to landfills and/orincinerators.

PET-Containing Waste Plastic from a Plastic Article ManufacturingFacility

Another source of PET-containing waste plastic includes plastic articlemanufacturing facilities. These facilities may produce, for example,plastic bottles, plastic containers, plastic caps, plastic lids, plasticstraws, plastic bags, plastic films, and a variety of standard andcustomized plastic goods. A variety of manufacturing methods may beused, including but not limited to, casting, rotational molding,injection molding, blow molding, thermoforming (vacuum forming),extrusion, and 3D printing. These processes may produce waste plasticdue to errors in the process or as an inherent result of the process.For example, the waste plastic may comprise portions of defectiveplastic articles having deformities, surface imperfections, and/orbrittle parts. The waste plastic may also include other products ofmolding processes, for example intermediate molded products, such asbottle preforms or sheets. The waste plastic may also be scrap plasticremoved from plastic articles during the manufacturing process, such asedge trim from film or sheet plastic. These waste plastics may generallycomprise some amount of (or even predominantly) PET. The waste plasticmay also be removed or expelled from the manufacturing apparatus used tocreate plastic articles as a part of a manufacturing start up or windingdown process.

PET-Reclaimer Facility

As noted above, the one or more PET-containing materials used asfeedstock for the chemical recycling facility, and particularly to asolvolysis facility, may include one or more co-products from areclaimer facility, and particularly a PET reclaimer facility. In anembodiment or in combination with any embodiment mentioned herein, theportion of PET-containing materials may comprise at least twoPET-containing reclaimer co-products.

FIG. 4 shows a schematic of an exemplary reclaimer facility 800illustrating typical rPET products and co-products derived from thereclaimer facility 800. As shown, a plastic feed 802, for example from aMRF, may be fed to a reclaimer zone 810. Reclaimer zone 810 generallycomprises various separation processes (described below) that produce asubstantially pure r-PET plastic stream 812 comprising at least 99, orat least 99.9 weight percent PET on a dry plastic basis. Reclaimer zone810 may also produce one or more reclaimer co-products, including wetfines 803, colored plastic 804, eddy current reject 805, flake sorterreject 806, and/or dry fines 807.

The r-PET plastic stream 812 may comprise a quantity of rPET plasticflake, which can be recovered as an rPET flake stream 814. Additionallyor alternatively, at least a portion of the r-PET plastic stream 812 maybe fed to a densification (e.g., pelletization) zone 820. Densificationzone 820 generally comprises various processes (described below) thatconvert the rPET flake from stream 812 into desirable rPET pellets 818.Densification zone 820 may also produce one or more reclaimerco-products, including PET purge materials 815, wet fines 816, and/ordry fines 817.

FIG. 5 shows a schematic of an exemplary reclaimer facility 800illustrating some specific processing steps that are carried out withinthe reclaimer facility 800 and the resulting products and co-productsproduced therefrom. While the processing steps are shown and describedbelow in a particular order, it should be understood that otherreclaimer facilities may perform one or more of the processing steps ina different order than shown in the figures and described herein and/oromit processing steps shown and described and/or include additionalprocessing steps not shown or described.

As shown in FIG. 5 , a quantity of baled plastic 801 may be provided tothe reclaimer facility 800 from a MRF facility, and fed to a dewiringdevice 830 and/or debaler 832 to produce a quantity of loose plasticwaste material. The dewiring device 830 may be used to avoid injuryrisks related to manual dewiring. The debaler 832 generally comprisesone or more wide blades that contact and break-up the dewired bales intothe loose plastic waste material. The loose plastic waste can then beconveyed 834, for example by a belt or pnuematic conveyor, to a heavyremoval process 836. The heavy removal 836 may use gravity and/or apneumatic conveyor to cause “heavier” components (e.g., densitiesgreater than 2 g/cc) to drop out of the conveyed stream. Such heaviercomponents can include metals, rocks, sand, and the like. However, someamount of PET and/or other plastic materials may also be intentionallyor unintentionally removed along with the heavier components, and thusthe metals, plastics and other components removed at this stage may berecovered as a heavies-containing (e.g., metal-containing) reclaimerco-product 837.

The plastic waste with the heavier components removed can then be passedto a friction washer 838, where food or other substances stuck to theplastic waste is washed away with a water stream and/or by contactingthe plastic waste with bumpers to remove the food or material from theplastic. In this and other steps that include a water wash or rinsestep, the water stream 839 generated can be filtered 840, eitherseparately or together with water streams from other steps describedherein. The filter 840 will be occasionally cleaned, and the removedsolids may include PET. Additionally or in the alternate, the filtratemay comprise some amount of PET and/or other plastic materials. Eitheror both of the solids and/or PET-containing filtrate from the filtrationprocess may be in the form of wet fines 841, which can be recovered as areclaimer co-product. As used herein, the terms “filtration” and“filtering” and “filter(ed)” refer to processes and/or apparatuses forperforming solid/liquid separation, which includes, but is not limitedto, the use of media, centrifugal separation, and/or settling.

After friction washer 838, the plastic waste can then be subjected toone or more near infrared (NIR), optical, and/or manual sorting steps toremove colored plastics and/or other plastic and non-plastic materialsthat are not recognized by the sorter (manual or mechanical) as aPET-containing plastic material. As shown, the process includes two NIRsorters 842, 844 and manuaral sorting steps 846, 848 resulting in fourstreams of colored plastic mixtures 843, 845, 847, 849 as reclaimerco-products. The NIR and optical sorters will typically reject anythingthat the sensors do not recognize entirely as clear PET material. Thisreject may include PET bottles with labels and/or colored caps. However,certain NIR and/or optical sorters may not have the capacity to “see”and reject black colored plastics, such as clam shell containers withcarbon black portions. Thus, often black colored plastics do not getrejected by these sorters. Additionally, the air blowers are locateddownstream of the sensors, and some amount of clear PET material mayalso be rejected along with the colored PET material. The manual sorterswill typically “pull” or reject any material that is not obviously aclear PET bottle or material, as well as PET bottles with liners orother known problematic components for the downstream reclaimerprocesses. Thus, the colored plastic mixtures derived from theseprocesses typically comprise some amount of PET and/or other plasticmaterials in the form of a colored plastic-containing mixture, which maybe recovered as a reclaimer co-product.

After NIR, optical, and/or manual sorting steps, the plastic waste maythen be passed to an optional eddy current separator 850 to remove anymetals remaining with the waste plastic and protect downstream processesfrom damage. An eddy current separator uses an electrical field at theend of a conveyor belt to repel conductive, non-ferrous metals, such asaluminum, and does not affect non-conductive materials such as plastic.When the stream of plastic waste nears the end of the conveyor belt, theeddy current alters the natural, gravity-induced trajectory of thenon-ferrous metal and ejects the non-ferrous metal from the stream alonga different trajectory than the non-conductive materials. A dividerplate sits between the pathways defined by the two trajectories, whichallows the ejected and non-ejected components to be separated. Duringthe separation, some amount of plastic articles and/or plastic flake maycome into contact with the non-ferrous metal components and beunintentionally ejected along the incorrect trajectory. Thus, theseparated non-ferrous metals may comprise some amount of PET and/orother plastic materials, which may be recovered as a metal-containingreclaimer co-product 851. Additionally, the eddy current separator maybe coupled with a grinder 852 (upstream or downstream of the eddycurrent separator 850), which may produce plastic fines that can also berecovered as a reclaimer co-product.

After the optional eddy current separator 850 and/or grinder 852, theplastic waste can then be passed to a density separation stage 854, suchas a sink-float separation stage, which will generally separatecomponents that are less dense than PET (e.g., polyolefins) from theplastic waste, and a mechanical dewatering process 856. As noted above,the waste water from such processes is filtered 840, 860, and the solidsand/or filtrate may be recovered as wet fines 841, 861, or otherreclaimer co-product (such as polyolefins stream 859).

The plastic waste can then be passed to another NIR 862 and/or opticalsorter, which again will typically reject anything that the sensors donot recognize entirely as clear PET. The plastic waste at this stage hastypically undergone a size reduction process, such as grinding, and thusthe rejected material is generally in the form of plastic flake (definedbelow). This processes is intended to remove PVC, for example fromlabels, and other plastic materials that have a similar density to PETand were not removed during density separation. However, similar to theprevious NIR and optical sorters, the rejected flake may include someamount of PET and may be recovered as a flake reject reclaimerco-product 863.

At this point, the plastic waste will typically have a high PET content(e.g., at least 99 or at least 99.9 weight percent) and can be dried 864and prepared for packaging 870 as an rPET flake product 814. When adryer 864 is used, some amount of dry fines (defined below) may beseparated from the flake product in the dryer 864 or in a downstreamconveyor 866 and/or dust collector 868. Although the dry fines alsotypically have a high PET content, they are not desirable as rPETfeedstock for mechanical recycling facilities. However, the dry finesmay be recovered as a dry fines reclaimer co-product 865, 869. It shouldbe understood that dryers and dust collectors may be used elsewhereupstream or downstream in the reclaimer facility, and the dry finesrecovered from these locations may also be recovered as a reclaimerco-product.

Some reclaimer facilities will also include a densifying process toconvert the rPET flake into desirable rPET pellets. As used herein,“densifying” refers to a process of condensing and pelletizing,agglomerating, or partial melting a quantity of plastic particles havinga D90 particle size of less than 0.32 cm (⅛ inch) to form solidparticulates (e.g., pellets) having a D90 particle size of 0.32 cm (⅛inch) to 2.54 cm (1 inch). The densifying process generally comprises anextruder 880, wherein the rPET flake is melted and passed through anextrusion barrel. A pelletizer 882 then operates to form the extrudedrPET into pellets (typically having a D90 of not more than 2.54 cm (1inch)). The pellets are then rinsed (which may result in recoverablePET-containing wet fines), dried (which may result in recoverablePET-containing dry fines) and packaged 890 for shipment to themechanical recycling facilities as an rPEt pellets product 892. However,when the extruder is turned off, some amount of melted rPET is purgedand allowed to solidify, for example into chunks of PET material,without being converted to pellets. This purge material may be recoveredas a PET purge material reclaimer co-product 881. Additionally, thepelletization is typically performed in water, and the filtrate and/orsolids from the filtered water stream may be recovered as a reclaimerco-product (e.g., wet fines 883). Finally, the dryers 884 and conveyors886, 888, used in the pellet packaging process will typically beequipped with dust collectors, and the dry fines may also be recoveredas dry fines reclaimer co-products 885, 887, 889.

The compositions of the reclaimer co-products and processing stepswithin the chemical recycling facility are described in greater detailbelow. However, it should be understood that the descriptions below mayalso describe the compositions and processing of the otherPET-containing materials (i.e., the PET-containing MRF products orco-products, sorted plastic-containing mixtures, and/or PET-containingwaste plastic from a plastic article manufacturing facility) within thescope of the present technology.

Wet Fines

As described above, reclaimer wet fines may be separated from theplastic waste and recovered, for example as filtrate and/or solids froma filtration process. As used herein, “reclaimer wet fines” refers to astream or batch of PET-containing plastic particles separated from awaste plastic within a reclaimer facility and having a water content,when first isolated from the waste plastic within the reclaimerfacility, of at least 2% by weight based upon the total weight of thereclaimer wet fines, and the plastic particles have a D90 of less than0.32 cm (⅛ inch). In an embodiment or in combination with any embodimentmentioned herein, a quantity of reclaimer wet fines is fed to thechemical recycling facility, and at least a portion of the quantity ofreclaimer wet fines is depolymerized therein.

In an embodiment or in combination with any embodiment mentioned herein,the quantity of PET-containing reclaimer wet fines comprises a watercontent of at least 2, at least 5, at least 10, at least 20, at least30, at least 40, or at least 50 weight percent. The quantity ofPET-containing reclaimer wet fines may comprise at least 1, at least 5,at least 10, at least 20, at least 30, at least 40, or at least 50weight percent of plastic particles having a D90 of less than 0.32 cm (⅛inch). The quantity of PET-containing reclaimer wet fines may compriseat least 90, at least 95, or at least 99 weight percent PET on a drybasis (i.e., excluding the moisture content).

In an embodiment or in combination with any embodiment mentioned herein,at least 40, at least 50, at least 60, at least 70, at least 80, atleast 90, at least 95, or at least 99 weight percent of the watercontent from said quantity of PET-containing reclaimer wet fines may beremoved before depolymerizing. The water content may be removed bypassive drying (e.g., sitting in storage) or use of a dryer or otheractive drying process. In one or more embodiments, at least a portion ofthe plastic particles from the PET-containing reclaimer wet fines may bedensified (e.g., agglomerated or pelletized) to form a quantity ofdensified PET-containing particles having a D90 of 0.32 cm (⅛ inches) to2.54 (1 inch) before depolymerizing. The quantity of densifiedPET-containing particles may be liquified (e.g., dissolved or melted) toform a liquified plastic material before depolymerizing. One or more ofwater removal, densifying, and/or liquifying may be performed within thechemical recycling facility or before feeding the quantity of wet finesto the chemical recycling facility.

In an embodiment or in combination with any embodiment mentioned herein,the quantity of PET-containing reclaimer wet fines (including thequantity of densified PET-containing particles and/or the liquidifedplastic material) may be fed to a solvolysis facility within thechemical recycling facility wherein the depolymerizing occurs. Thequantity of PET-containing reclaimer wet fines (including the quantityof densified PET-containing particles and/or the liquidifed plasticmaterial) may comprise at least 90, at least 95, or at least 99 weightpercent PET on a dry basis. The quantity of PET-containing reclaimer wetfines (including the quantity of densified PET-containing particlesand/or the liquidifed plastic material) may comprise not more than 10,not more than 8, not more than 6, not more than 4, not more than 2, ornot more than 1 weight percent halogens on a dry basis. The quantity ofPET-containing reclaimer wet fines (including the quantity of densifiedPET-containing particles and/or the liquidifed plastic material) maycomprise not more than 50, not more than 40, not more than 30, not morethan 20, not more than 10, not more than 5, or not more than 1 weightpercent polyolefins on a dry basis.

Colored Plastic-Containing Mixture

As described above, colored plastic-containing mixtures may be separatedfrom the plastic waste in a PET reclaimer and recovered. Additionally oralternatively, colored plastic-containing mixtures can be separated in aMRF facility and similarly recovered. As used herein, the term “coloredplastic-containing mixture” refers to: (a) a plastic-containing materialidentified by a reclaimer or MRF as a colored plastic or identified by areclaimer or MRF as non-clear rPET; or (b) any plastic-containingmaterial separated by a reclaimer or MRF other than dry fines, wetfines, reclaimer clear rPET product, rocks, biomass, metal, or fiber. Inan embodiment or in combination with any embodiment mentioned herein, aquantity of a PET-containing reclaimer colored plastic-containingmixture and/or MRF colored plastic-containing mixture is fed to thechemical recycling facility, and at least a portion of the quantity ofthe PET-containing reclaimer colored plastic-containing mixture and/orMRF colored plastic-containing mixture is depolymerized therein.

In an embodiment or in combination with any embodiment mentioned herein,the quantity of colored plastic-containing mixture comprises at least 1,at least 10, at least 20, at least 40, at least 60, at least 80, or atleast 90 and/or not more than 99.9 or not more than 99 weight percentPET on a dry basis. The quantity of colored plastic-containing mixturemay comprise from 1 to 99.9 or 50 to 99 weight percent PET on a drybasis. The quantity of colored plastic-containing mixture may compriseat least 1, at least 10, at least 20, at least 40, at least 60, at least80, at least 90, at least 95, at least 99, or at least 99.9 weightpercent non-clear PET (e.g., green PET) on a dry basis. The quantity ofcolored plastic-containing mixture may comprise not more than 10, notmore than 8, not more than 6, not more than 4, not more than 2, or notmore than 1 weight percent halogens on a dry basis. The quantity ofcolored plastic-containing mixture may comprise at least 1, at least 2,at least 4, at least 6, or at least 8 weight percent and/or not morethan 90, not more than 80, not more than 70, not more than 60, not morethan 50, not more than 40, not more than 30, not more than 20, or notmore than 10 weight percent polyolefins on a dry basis. The quantity ofcolored plastic-containing mixture may comprise from 1 to 90, from 2 to70, from 4 to 50, from 6 to 30, or from 8 to 10 weight percentpolyolefins on a dry basis. The quantity of colored plastic-containingmixture may comprise at least 0.1, at least 1, at least 10, at least 20,at least 30, at least 40, at least 50, at least 60, at least 70, atleast 80, or at least 90 weight percent non-clear PET and/or othercolored plastic material on a dry plastic basis. The quantity of coloredplastic-containing mixture may comprise at least 0.1, at least 1, atleast 10, at least 20, at least 30, at least 40, at least 50, at least60, at least 70, at least 80, or at least 90 weight percent PVC, nylon,and/or copolyesters on a dry basis.

In an embodiment or in combination with any embodiment mentioned herein,the quantity of colored plastic-containing mixture may be fed directlyto a solvolysis facility within the chemical recycling facility withoutbeing fed to a preprocessing and/or separation facility or undergoing apreprocessing and/or separation process within or separate from thechemical recycling facility. However, at least a portion of the quantityof colored plastic-containing mixture may be fed to at least one densityseparation stage before the depolymerizing, thereby producing aPET-enriched stream that is fed into a solvolysis facility within thechemical recycling facility. The at least one density separation stagemay comprise at least two density separation stages.

PET and Metal-Containing Reclaimer Co-product

As described above, metal components may be separated from the plasticwaste in a reclaimer facility, for example in a heavy removal processand/or eddy current separator, and these metal components may includesome amount of PET material and be recovered as PET and metal-containingreclaimer co-product. As used herein, the term “PET and metal-containingreclaimer co-product” refers to materials from a magnetic separator, aneddy current separator, or other metal separator in a PET reclaimerfacility that are not recovered as rPET product. In an embodiment or incombination with any embodiment mentioned herein, a quantity of PET andmetal-containing reclaimer co-product may be fed to the chemicalrecycling facility, and at least a portion of the quantity of PET andmetal-containing reclaimer co-product is depolymerized therein.

In an embodiment or in combination with any embodiment mentioned herein,the quantity of PET and metal-containing reclaimer co-product comprisesat least 0.1, at least 1, at least 5, at least 10, or at least 15 weightpercent metals on a dry basis. However, the metal content that is fed tothe solvolysis facility for depolymerization may be limited. Thus, atleast a portion, at least 90 weight percent, at least 95 weight percent,at least 99 weight percent, or at least 99.9 weight percent of themetals may be separated and removed from the plastics beforedepolymerizing, as described below. The separation or removal may bedone as a continuous separation process (e.g., a solid/liquid separator)and/or as a batch separation process (e.g., purge process) and may beperformed in the preprocessing facility and/or the solvolysis facility(such as the front end of the solvolysis facility). Whether a separationstep is used or not, the feedstock to the solvolysis facility and/ordepolymerization processes may be not more than 10, not more than 8, notmore than 6, not more than 4, not more than 2, or not more than 1 weightpercent metals on a dry basis. The metals may include one type of metalor more than one type of metal and may include ferrous and/ornon-ferrous metals. The metals may comprise one or more non-ferrousmetals such as aluminum, copper, lead, nickel, tin, titanium, zinc,and/or alloys thereof. The metals may comprise one or more ferrousmetals such as iron, steel, stainless steel, carbon steel, austentic,martensitic, duplex stainless steels, ferritic stainless steel, and/oralloys thereof. The quantity of PET and metal-containing reclaimerco-product may comprise at least 0.1, at least 1, at least 10, at least20, at least 40, at least 60, or at least 80 weight percent PET on a drybasis.

In an embodiment or in combination with any embodiment mentioned herein,the quantity of PET and metal-containing reclaimer co-product comprisesplastic flakes and at least 0.1, at least 1, at least 5, at least 10, orat least 15 weight percent metals on a dry basis. As used herein, theterm “plastic flakes” refers to plastic particles having a D90 particlesize of 0.32 cm (⅛ inches) to 2.54 cm (1 inch). At least a portion ofthe plastic flakes can be separated from the metals beforedepolymerizing. This separation may occur within the chemical recyclingfacility, for example in the preprocessing facility and/or solvolysisfacility, or before the PET and metal-containing reclaimer co-product isfed to the chemical recycling facility. The separating may comprisefeeding at least a portion of the quantity of reclaimer co-product intoat least one density separation stage to separate at least a portion ofthe plastic flakes from the metals. The separated portion of plasticflakes may be fed into a solvolysis facility within the chemicalrecycling facility. The metals, which may have a portion of plasticflake separated therefrom, may be fed into a partial oxidation (POX)gasifier.

In an embodiment or in combination with any embodiment mentioned herein,the quantity of PET and metal-containing reclaimer co-product does notundergo separation prior to being fed to the chemical recyclingfacility. For example, both the metals and the plastic flake may be fedto the solvolysis facility within the chemical recycling facility, andthe metal may be removed by a solid/liquid separator (e.g., filter)and/or purge in the solvolysis facility. Additionally, the metals may befed into a POX gasifier without having the portion of plastic flakeseparated therefrom.

In an embodiment or in combination with any embodiment mentioned herein,the quantity of PET and metal-containing reclaimer co-product comprisesplastic articles and at least 0.1, at least 1, at least 5, at least 10,or at least 15 weight percent metals on a dry basis. As used herein, theterm “plastic articles” refers to baled or unbaled plastic materialshaving a D90 particle size of greater than 2.54 cm (1 inch). The plasticarticles may be in the form of compressed bales. The plastic articlesmay be processed, for example by debaling, grinding, chopping,shredding, and/or pulverizing, to produce a debaled quantity of plasticarticles and metals and/or to reduce the size of the plastic articles toform plastic particulate solids having a D90 particle size of less than2.54 cm (1 inch).

In an embodiment or in combination with any embodiment mentioned herein,at least a portion of the plastic articles and/or plastic particulatesolids can be separated from the metals before depolymerizing. Thisseparation may occur within the chemical recycling facility, for examplein the preprocessing facility and/or solvolysis facility, or before thePET and metal-containing reclaimer co-product is fed to the chemicalrecycling facility. The separating may comprise feeding at least aportion of the plastic articles and/or plastic particulate solids intoat least one density separation stage to separate at least a portion ofthe plastic articles and/or plastic particulate solids from the metals.The separated portion of plastic articles and/or plastic particulatesolids may be fed into a solvolysis facility within the chemicalrecycling facility. The metals, which have a portion of plastic articlesand/or plastic particulate solids separated therefrom, may be fed into apartial oxidation (POX) gasifier.

Similar to the plastic flake, in an embodiment or in combination withany embodiment mentioned herein, both the metals and the plasticarticles and/or plastic particulate solids may be fed to the solvolysisfacility within the chemical recycling facility, and the metal may beremoved by a filter and/or purge in the solvolysis hydrolysis facility.Additionally, the metals may be fed into a POX gasifier without havingthe portion of plastic articles and/or plastic particulate solidsseparated therefrom.

In an embodiment or in combination with any embodiment mentioned herein,the quantity of PET and metal-containing reclaimer co-product comprisesplastic fines and at least 0.1, at least 1, at least 5, at least 10, orat least 15 weight percent metals on a dry basis. As used herein, theterm “plastic fines” refers to plastic particulates having a D90particle size of less than 0.32 cm (⅛ inch). At least a portion of theplastic fines may be densified (e.g., agglomerated or pelletized) toproduce densified PET-containing particles before depolymerizing. Thedensification may occur within the chemical recycling facility or beforethe PET and metal-containing reclaimer co-product is fed to the chemicalrecycling facility. The densified PET-containing particles may have aD90 particle size of 1 to 10 mm, 2 to 8 mm, or 3 to 5 mm. Thedensification may occur without separating the all or a portion of themetals in the reclaimer product, and thus the densified PET-containingparticles may comprise at least a portion of the metals. The densifiedPET-containing particles may be fed directly to a solvolysis facilitywithin said chemical recycling facility (i.e., without undergoing apreprocessing or separation process within the chemical recyclingfacility or separate from the chemical recycling facility).

In an embodiment or in combination with any embodiment mentioned herein,the metals separated from the plastic material of the PET andmetal-containing reclaimer co-product (i.e., the metals separated fromthe plastic flake, plastic articles, and/or plastic fines using any oneor more of the preprocessing or separation methods described in thissection or elsewhere in the application) may be recovered in ametal-containing stream, for example with a portion of the plasticflake, plastic articles, and/or plastic fines or other plasticmaterials, and fed to a pyrolysis facility, and in one or moreembodiments to a pyrolysis reactor within the pyrolysis facility.

Reclaimer Flake Reject

As described above, PET and PVC-containing reclaimer flake reject may beseparated from the plastic waste in a PET reclaimer and recovered. Asused herein, “reclaimer flake reject” refers to a waste mixture ofplastic, comprising at least PET and at least 0.1 weight percent PVC ona dry basis, from a reclaimer facility and having a D90 particle size of0.32 cm (⅛ inch) to 2.54 cm (1 inch). In an embodiment or in combinationwith any embodiment mentioned herein, a quantity of PET andPVC-containing flake reject is fed to a chemical recycling facility, andat least a portion of the quantity of PET and PVC-containing flakereject is depolymerized therein.

In an embodiment or in combination with any embodiment mentioned herein,the quantity of reclaimer flake reject is enriched in PVC and depletedin polyolefins relative to the plastic waste. The quantity of reclaimerflake reject may comprise at least 0.1, at least 1, at least 10, atleast 20, at least 40, at least 60, or at least 80 weight percent PET ona dry basis. The quantity of reclaimer flake reject may comprise atleast 1, at least 5, at least 10, or at least 15 weight percent of PVCon a dry basis. The quantity of reclaimer flake reject may comprise atleast 0.1, at least 1, or at least 5 weight percent and/or not more than20, not more than 15, or not more than 10 weight percent polyolefins ona dry basis. The quantity of reclaimer flake reject may comprise from0.1 to 20, from 1 to 15, or from 5 to 10 weight percent polyolefins on adry basis.

In an embodiment or in combination with any embodiment mentioned herein,at least a portion of the quantity of reclaimer flake reject may be fedinto at least one density separation stage before depolymerizing, inwhich a PET-enriched stream and a polyolefin-enriched stream can beproduced from a waste plastic stream comprising the flake reject. In anembodiment or in combination with any embodiment mentioned herein, theportion of the quantity of reclaimer flake reject may be the onlyplastic material in the waste plastic stream fed to the at least onedensity separation stage. However, in other embodiments, the portion ofthe quantity of reclaimer flake reject may be mixed with one or moreother plastic materials in the waste plastic stream fed to the at leastone density separation stage. The PET-enriched stream may be fed into asolvolysis facility. The polyolefin-enriched stream may be fed into apartial oxidation (POX) gasifier. The polyolefin-enriched stream may befed into a pyrolysis facility, and may be fed to a pyrolysis reactorwithin the pyrolysis facility. Additionally, or alternatively, thepolyolefin-enriched stream may be fed into an energy recovery facility.

In an embodiment or in combination with any embodiment mentioned herein,at least a portion of the quantity of PET and PVC-containing reclaimerflake reject may be fed into a mechanical dewatering apparatus beforedepolymerizing. The portion of the quantity of reclaimer flake rejectmay then be fed into a thermal dryer after the mechanical dewateringapparatus.

In an embodiment or in combination with any embodiment mentioned herein,at least a portion of the quantity of PET and PVC-containing reclaimerflake reject may be fed directly to a solvolysis facility within saidchemical recycling facility (i.e., without undergoing a preprocessing orseparation process within the chemical recycling facility or separatefrom the chemical recycling facility).

Solidified Purge Material

As described above, solidified purge material may be derived fromunusable or undesirable liquified plastic material, for example from aPET (rPET) reclaimer facility, PET articles manufacturer (molder),and/or polymer manufacturing facility, that is allowed to solidify andcan be recovered. As used herein, the term “solidified purge material”refers to a plastic waste removed from any molten polymer processingapparatus or portion thereof while the apparatus is not producing anintended product (e.g., pellets, bottles, and other plastic articles),including but not limited to an extruder, filter, pelletizer, reactor,conduit, and the like, that was molten within the molten polymerprocessing apparatus but was permitted to solidify outside of saidapparatus. The solidified material may be generally un-shaped and/ornon-pelletized, and may be in the form of solid plastic chunks (e.g.,plastic chunks removed from an extruder barrel that have not passedthrough the extruder die). The solidified plastic material may alsoinclude intermediate molded products. The solidified plastic materialmay include clear and/or colored plastics. In an embodiment or incombination with any embodiment mentioned herein, a quantity ofPET-containing solidified purge material is fed to a chemical recyclingfacility, and at least a portion of the quantity of PET-containingsolidified purge material is depolymerized therein.

In an embodiment or in combination with any embodiment mentioned herein,the quantity of PET-containing solidified purge material comprises atleast 90, at least 95, at least 99 or at least 99.9 weight percent PETon a dry basis. The quantity of PET-containing solidified purge materialmay comprise at least 0.1, at least 1, at least 10, at least 20, atleast 40, at least 60, or at least 80 weight percent co-polyesters on adry basis. The quantity of PET-containing solidified purge material maycomprise at least 95, at least 98, at least 99, or at least 99.9 weightpercent of materials that are solid at the processing temperature of themolten polymer processing apparatus (e.g., glass, metals, and otherfillers). The quantity of PET-containing solidified purge material maycomprise not more than 50, not more than 40, not more than 30, not morethan 20, not more than 10, or not more than 1 weight percent polyolefinson a dry basis. The quantity of PET-containing solidified purge materialmay comprise not more than 20, not more than 15, not more than 10, notmore than 5, or not more than 1 weight percent PVC on a dry basis.

In an embodiment or in combination with any embodiment mentioned herein,at least a portion of the quantity of PET-containing solidified purgematerial may be fed directly into a solvolysis facility within thechemical recycling facility (i.e., without undergoing a preprocessing orseparation process within the chemical recycling facility or separatefrom the chemical recycling facility). At least a portion of thequantity of PET-containing solidified purge material may be reduced insize, for example by a mechanical size reduction process. The mechanicalsize reduction process may comprise shredding (e.g., using a plasticshredder), chopping, grinding, guillotine, dropping, and/or smashing theportion of the solidified purge material, to form a quantity of plasticparticulate solids before depolymerizing.

In an embodiment or in combination with any embodiment mentioned herein,the resulting plastic particulate solids may have a D90 particle size ofless than 15.24 cm (6 inches), not more than 12.7 cm (5 inches), notmore than 10.16 cm (4 inches), not more than 7.62 cm (3 inches), notmore than 5.08 cm (2 inches), or not more than 2.54 cm (1 inch). When ashredder is used, the solidified purge material may result in plasticparticulate solids having a D90 particle size of less than 5.08 cm (2inches), or less than 2.54 cm (1 inch). In the size reduction processesdescribed above, or in collection of the purge material, a quantity ofdry fines, strings, strands, and/or fibrous materials may be producedfrom the solidified purge materials and recovered. For example, when ashredder is used, the process may produce a quantity of plastic fines.However, the use of a grinder can be avoided, and thus the process canproduce less than 10%, less than 5%, less than 2%, or less than 1%plastic fines. The quantity of these recovered materials may bedensified into plastic particles having a D90 particle size of 0.32 cm(⅛ inches) to 2.54 cm (1 inch) before depolymerizing. For example, ascreener can be used to recover large particulates (over 2.54 cm (1inch)) and fines (less than 0.32 cm (⅛ inch)). The large particles canbe recycled back to the shredder. The fines can be densified asdescribed above.

Dry Fines

As described above, dry fines may be produced from the processing (e.g.,conveying, drying, densification, extruding, packaging, centrifugationprocesses, and/or grinding) and/or conveyance of plastic materials,which can be collected in a dryer or dust collector and recovered. Asused herein, the term “dry fines” refers to waste plastic particles froma PET reclaimer facility and/or a manufacturer of PET articles, havingan average particle size of less than 0.32 cm (⅛ inch) and a moisturecontent of less than 2% by weight. In an embodiment or in combinationwith any embodiment mentioned herein, a quantity of PET-containing dryfines is fed to a chemical recycling facility, and at least a portion ofthe quantity of PET-containing dry fines is depolymerized therein.

In an embodiment or in combination with any embodiment mentioned herein,the quantity of PET-containing dry fines comprises at least 90, at least95, at least 99, or at least 99.9 weight percent PET on a dry basis. Thequantity of PET-containing dry fines may comprise at least 0.1, at least1, at least 10, at least 20, at least 40, at least 60, or at least 80weight percent co-polyesters on a dry basis. The quantity ofPET-containing dry fines may comprise not more than 50, not more than40, not more than 30, not more than 20, not more than 10, or not morethan 1 weight percent polyolefins on a dry basis. The quantity ofPET-containing dry fines may comprise not more than 20, not more than15, not more than 10, not more than 5, or not more than 1 weight percentPVC on a dry basis.

In an embodiment or in combination with any embodiment mentioned herein,at least a portion of the quantity of PET-containing dry fines is feddirectly to the chemical recycling facility (i.e., without undergoing apreprocessing or separation process within the chemical recyclingfacility or separate from the chemical recycling facility). This may beaccomplished using a conveyance system interconnecting the chemicalrecycling facility to a PET reclaimer facility, a manufacturer of PETarticles, and/or polymer manufacturing facility. The dry fines may alsobe delivered in sacks or bags.

Dry fines may pose some risk of explosion. While the dry fines do notgenerally arrive in an explosive state, conveying the dry fines causesseparation and air exposure, making the dry fines potentially explosive.Explosive concentrations can also exist in storage piles. Thus, the dryfines may be screened to remove and recover dry fines dry fines having aparticle size of less than 1000 μm, less than 800 μm, less than 600 μm,or less than 420 μm. At least a portion of the PET-containing dry finesrecovered in the screening above or other processes may be densified(e.g., agglomerated or pelletized) to produce densified PET-containingparticles before depolymerizing, thereby reducing or eliminating theexplosive risk. In an embodiment or in combination with any embodimentmentioned herein, the densified plastic particles have a D90 particlesize of 0.32 cm (⅛ inches) to 2.54 cm (1 inch). In one or moreembodiments, the densified plastic particles may be fed into asolvolysis facility within the chemical recycling facility.

Delivery of Waste Plastic

The chemical recycling facility 10 may also include infrastructure forreceiving waste plastic (e.g., PET-containing reclaimer co-products,PET-containing municipal recycling facility (MRF) products orco-products, sorted plastic-containing mixtures, PET-containing wasteplastic from a plastic article manufacturing facility, and/or other MPW)as described herein to facilitate delivery of the waste plastic by anysuitable type of vehicle including, for example, trains, trucks, and/orships. Such infrastructure may include facilities to assist withoffloading the waste plastic from the vehicle, as well as storagefacilities and one or more conveyance systems for transporting the wasteplastic from the offloading zone to the downstream processing zones.Such conveyance systems may include, for example, pneumatic conveyors,belt conveyors, bucket conveyors, vibrating conveyors, screw conveyors,cart-on-track conveyors, tow conveyors, trolley conveyors, front-endloaders, trucks, and chain conveyors.

The waste (e.g., PET-containing reclaimer co-products, PET-containingmunicipal recycling facility (MRF) products or co-products, sortedplastic-containing mixtures, PET-containing waste plastic from a plasticarticle manufacturing facility, and/or other MPW) introduced into thechemical recycling facility 10 may be in several forms including, butnot limited to, whole articles, particulates (e.g., comminuted,pelletized, fiber plastic particulates), bound bales (e.g., wholearticles compressed and strapped), unbound articles (i.e., not in balesor packaged), containers (e.g., box, sack, trailer, railroad car, loaderbucket), piles (e.g., on a concrete slab in a building), solid/liquidslurries (e.g., pumped slurry of plastics in water), and/or loosematerials conveyed physically (e.g., particulates on a conveyor belt) orpneumatically (e.g., particulates mixed with air and/or inert gas in aconvey pipe).

As used herein, the term “waste plastic particulates” refers to wasteplastic having a D90 of less than 1 inch. In an embodiment or incombination with any embodiment mentioned herein, the waste plasticparticulates can be MPW particulates. A waste plastic or MPW particulatecan include, for example, comminuted plastic particles that have beenshredded or chopped, or plastic pellets. When whole or nearly wholearticles are introduced into the chemical recycling facility 10 (orpreprocessing facility 20), one or more comminuting or pelletizing stepsmay be used therein to form waste plastic particulates (e.g., MPWparticulates). Alternatively, or in addition, at least a portion of thewaste plastic introduced into the chemical recycling facility 10 (orpreprocessing facility 20) may already be in the form of particulates.

The general configuration and operation of each of the facilities thatmay be present in the chemical recycling facility shown in FIG. 1 willnow be described in further detail below, beginning with thepreprocessing facility. Optionally, although not shown in FIG. 1 , atleast one of the streams from the chemical recycling facility may besent to an industrial landfill or other similar type of processing ordisposal facility.

Preprocessing

As shown in FIG. 1 , the unprocessed and/or partially processed wasteplastic, such as mixed plastic waste (MPW), may first be introduced intoa preprocessing facility 20 via stream 100. In preprocessing facility 20the stream may undergo one or more processing steps to prepare it forchemical recycling. As used herein, the term “preprocessing” refers topreparing waste plastic for chemical recycling using one or more of thefollowing steps: (i) comminuting; (ii) particulating; (iii) washing;(iv) drying; and (v) separation. As used herein, the term “preprocessingfacility” refers to a facility that includes all equipment, lines, andcontrols necessary to carry out the preprocessing of waste plastic.Preprocessing facilities as described herein may employ any suitablemethod for carrying out the preparation of waste plastic for chemicalrecycling using one or more of these steps, which are described infurther detail below.

Comminuting & Particulating

In an embodiment or in combination with any embodiment mentioned herein,the waste plastic (e.g., MPW) may be provided in bales of unsorted orpresorted plastic, or in other large, aggregated forms. The bales oraggregated plastics undergo an initial process in which they are brokenapart. Plastic bales can be sent to a debaler machine that comprises,for example, one or more rotating shafts equipped with teeth or bladesconfigured to break the bales apart, and in some instances shred, theplastics from which the bales are comprised. In one or more otherembodiments, the bales or aggregated plastics can be sent to aguillotine machine where they are chopped into smaller sized pieces ofplastic. The debaled and/or guillotined plastic solids can then besubjected to a sorting process in which various non-plastic, heavymaterials, such as glass, metal, and rocks, are removed. This sortingprocess can be performed manually or by a machine. Sorting machines mayrely upon optical sensors, magnets, eddy currents, pneumatic lifts orconveyors that separate based on drag coefficient, or sieves to identifyand remove the heavy materials.

In an embodiment or in combination with any embodiment mentioned herein,the waste plastic feedstock comprises plastic solids having a D90 thatis greater than one inch, greater than 0.75 inch, or greater than 0.5inch, such as used containers. Alternatively, or in addition, the wasteplastic feedstock may also comprise a plurality of plastic solids that,at one time, had at least one dimension of greater than one inch, butthe solids may have been compacted, pressed, or otherwise aggregatedinto a larger unit, such as a bale. In such embodiments wherein at leasta portion, or all, of the plastic solids have at least one dimensiongreater than one inch, greater than 0.75 inch, or 0.5 inch, thefeedstock may be subjected to a mechanical size reduction operation,such as grinding/granulating, shredding, guillotining, chopping, orother comminuting process to provide MPW particles having a reducedsize. Such mechanical size reduction operations can include a sizereduction step other than crushing, compacting, or forming plastic intobales.

In one or more other embodiments, the waste plastic may already haveundergone some initial separation and/or size-reduction process. Inparticular, the waste plastic may be in the form of particles or flakesand provided in some kind of container, such as a sack or box. Dependingupon the composition of these plastic solids and what kind ofpreprocessing they may have been subjected to, the plastic feedstock maybypass the debaler, guillotine, and/or heavies removal station andproceed directly to the granulating equipment for further sizereduction.

In an embodiment or in combination with any embodiment mentioned herein,the debaled or broken apart plastic solids may be sent to comminution orgranulating equipment in which the plastic solids are ground, shredded,or otherwise reduced in size. The plastic materials can be made intoparticles having a D90 particle size of less than 1 inch, less than ¾inch, or less than ½ inch. In one or more other embodiments, the D90particle size of the plastic materials exiting the granulating equipmentis from 1/16 inch to 1 inch, ⅛ inch to ¾ inch, ¼ inch to ⅝ inch, or ⅜inch to ½ inch.

Washing & Drying

In an embodiment or in combination with any embodiment mentioned herein,the unprocessed or partially processed waste plastic provided to thechemical recycling facility may comprise various organic contaminants orresidues that may be associated with the previous use of the wasteplastic. For example, the waste plastic may comprise food or beveragesoils, especially if the plastic material was used in food or beveragepackaging. Accordingly, the waste plastic may also contain microorganismcontaminants and/or compounds produced by the microorganisms. Exemplarymicroorganisms that may be present on the surfaces of the plastic solidsmaking up the waste plastic include E. coli, salmonella, C. dificile, S.aureus, L. monocytogenes, S. epidermidis, P. aeruginosa, and P.fluorescens.

Various microorganisms can produce compounds that cause malodors.Exemplary odor-causing compounds include hydrogen sulfide, dimethylsulfide, methanethiol, putrescine, cadaverine, trimethylamine, ammonia,acetaldehyde, acetic acid, propanoic acid, and/or butyric acid. Thus, itcan be appreciated that the waste plastic could present odor nuisanceconcerns. Therefore, the waste plastic may be stored within an enclosedspace, such as a shipping container, enclosed railcar, or enclosedtrailer until it can be processed further. In certain embodiments, theunprocessed or partially processed waste plastic, once it reaches thesite where processing (e.g., comminuting, washing, and sorting) of thewaste plastic is to occur, can be stored with the enclosed spaces for nomore than one week, no more than 5 days, no more than 3 days, no morethan 2 days, or no more than 1 day.

In an embodiment or in combination with any embodiment mentioned herein,the preprocessing facility 20 may also include equipment for or the stepof treating the waste plastic with a chemical composition that possessesantimicrobial characteristics, thereby forming treated particulateplastic solids. In some embodiments, this may include treating the wasteplastic with sodium hydroxide, high pH salt solutions (e.g., potassiumcarbonate), or other antimicrobial composition.

Additionally, in an embodiment or in combination with any embodimentmentioned herein, the waste plastic (e.g., MPW) may optionally be washedto remove inorganic, non-plastic solids such as dirt, glass, fillers andother non-plastic solid materials, and/or to remove biologicalcomponents such as bacteria and/or food. The resulting washed wasteplastic may also be dried to a moisture content of not more than 5, notmore than 3, not more than 2, not more than 1, not more than 0.5, or notmore than 0.25 weight percent water (or liquid), based on the totalweight of the waste plastic. The drying can be done in any suitablemanner, including by the addition of heat and/or air flow, mechanicaldrying (e.g., centrifugal), or by permitting evaporation of the liquidto occur over a specified time.

Separation

In an embodiment or in combination with any embodiment mentioned herein,the preprocessing facility 20 or step of the chemical recycling processor facility 10 may include at least one separation step or zone. Theseparation step or zone may be configured to separate the waste plasticstream into two or more streams enriched in certain types of plastics.Such separation is particularly advantageous when the waste plastic fedto the preprocessing facility 20 is MPW.

In an embodiment or in combination with any embodiment mentioned herein,the separation zone 22 (see FIG. 2 ) of the preprocessing facility 20may separate the waste plastic (e.g., MPW) into a PET-enriched stream112 and a PET-depleted stream 114 as shown in FIG. 2 . As used herein,the term “enriched” means having a concentration (on an undiluted dryweight basis) of a specific component that is greater than theconcentration of that component in a reference material or stream. Asused herein, the term “depleted” means having a concentration (on anundiluted dry weight basis) of a specific component that is less thanthe concentration of that component in a reference material or stream.As used herein, all weight percentages are given on an undiluted dryweight basis, unless otherwise noted.

When the enriched or depleted component is a solid, concentrations areon an undiluted dry solids weight basis; when the enriched or depletedcomponent is a liquid, concentrations are on an undiluted dry liquidweight basis; and when the enriched or depleted component is a gas,concentrations are on an undiluted dry gas weight basis. In addition,enriched and depleted can be expressed in mass balance terms, ratherthan as a concentration. As such, a stream enriched in a specificcomponent can have a mass of the component that is greater than the massof the component in a reference stream (e.g., feed stream or otherproduct stream), while a stream depleted in a specific component canhave a mass of the component that is less than the mass of the componentin a reference stream (e.g., feed stream or other product stream).

Referring again to FIG. 2 , the PET-enriched stream 112 of waste plasticwithdrawn from the preprocessing facility 20 (or separation zone 22) mayhave a higher concentration or mass of PET than the concentration ormass of PET in the waste plastic feed stream 100 introduced into thepreprocessing facility 20 (or separation zone 22). Similarly, thePET-depleted stream 114 withdrawn from the preprocessing facility 20 (orseparation zone 22) may be PET-depleted and have a lower concentrationor mass of PET than the concentration or mass of PET in the wasteplastic introduced into the preprocessing facility 20 (or separationzone 22). The PET-depleted stream 114 may also be PO-enriched and have ahigher concentration or mass of PO than the concentration or mass of POin the waste plastic (e.g., MPW) stream introduced into thepreprocessing facility 20 (or separation zone 22).

In an embodiment or in combination with any embodiment mentioned herein,when a MPW stream 100 is fed to the preprocessing facility (orseparation zone 22), the PET-enriched stream may be enriched inconcentration or mass of PET relative to the concentration or mass ofPET in the MPW stream, or the PET-depleted stream, or both, on anundiluted solids dry weight basis. For example, if the PET-enrichedstream is diluted with liquid or other solids after separation, theenrichment would be on the basis of a concentration in the undilutedPET-enriched stream, and on a dry basis. In one embodiment or incombination with any of the mentioned embodiments, the PET-enrichedstream 112 has a percent PET enrichment relative to the MPW feed stream(Feed-Based % PET Enrichment), the PET-depleted product stream 114(Product-Based % PET Enrichment), or both that is at least 10, at least20, at least 40, at least 50, at least 60, at least 80, at least 100, atleast 125, at least 150, at least 175, at least 200, at least 225, atleast 250, at least 300, at least 350, at least 400, at least 500, atleast 600, at least 700, at least 800, at least 900, or at least 1000%as determined by the formula:

${{Feed} - {Based}\%{PET}{Enrichment}} = {\frac{{PETe} - {PETm}}{PETm} \times 100{and}}$${{Product} - {Based}\%{PET}{Enrichment}} = {\frac{{PETe} - {PETd}}{PETd} \times 100}$

where PETe is the concentration of PET in the PET-enriched productstream 112 on an undiluted dry weight basis;

PETm is the concentration of PET in the MPW feed stream 100 on a dryweight basis; and

PETd is the concentration of PET in the PET-depleted product stream 114on a dry weight basis.

In an embodiment or in combination with any embodiment mentioned herein,when a stream comprising MPW 100 is fed to the preprocessing facility 20(or separation zone 22), the PET-enriched stream is also enriched inhalogens, such as fluorine (F), chlorine (Cl), bromine (Br), iodine (I),and astatine (At), and/or halogen-containing compounds, such as PVC,relative to the concentration or mass of halogens in the MPW feed stream100, or the PET-depleted product stream 114, or both. In one embodimentor in combination with any of the mentioned embodiments, thePET-enriched stream 112 has a percent PVC enrichment relative to the MPWfeed stream 100 (Feed-Based % PVC Enrichment), the PET-depleted productstream (Product-Based % PVC Enrichment), or both that is at least 1, atleast 3, at least 5, at least 7, at least 10, at least 15, at least 20,at least 40, at least 50, at least 60, at least 80, at least 100, atleast 125, at least 150, at least 175, at least 200, at least 225, atleast 250, at least 300, at least 350, at least 400, or at least 500% asdetermined by the formula:

${{Feed} - {Based}\%{PVC}{Enrichment}} = {\frac{{PVCe} - {PVCm}}{PVCm} \times 100{and}}$${{Product} - {Based}\%{PVC}{Enrichment}} = {\frac{{PVCe} - {PVCd}}{PVCd} \times 100}$

where PVCe is the concentration of PVC in the PET-enriched productstream 112 on an undiluted dry weight basis;

PVCm is the concentration of PVC in the MPW feed stream 100 on anundiluted dry weight basis; and

where PVCd is the concentration of PVC in the PET-depleted productstream 114 on an undiluted dry weight basis.

In one embodiment or in combination with any of the mentionedembodiments, when a MPW stream 100 is fed to the preprocessing facility20 (or separation zone 22), the PET-depleted stream 114 is enriched inpolyolefins relative to the concentration or mass of polyolefins in theMPW feed stream 100, the PET-enriched product stream 112, or both, on anundiluted solids dry basis. In one embodiment or in combination with anyof the mentioned embodiments, the PET-depleted stream 114 has a percentpolyolefin enrichment relative to the MPW feed stream 100 (Feed-Based %PO Enrichment), or relative to the PET-enriched product stream 112(Product-Based % PO Enrichment), or both that is at least 10, at least20, at least 40, at least 50, at least 60, at least 80, at least 100, atleast 125, at least 150, at least 175, at least 200, at least 225, atleast 250, at least 300, at least 350, at least 400, at least 500, atleast 600, at least 700, at least 800, at least 900, or at least 1000%as determined by the formula:

${{Feed} - {Based}\%{PO}{Enrichment}} = {\frac{{POd} - {POm}}{POm} \times 100{and}}$${{Product} - {Based}\%{PO}{Enrichment}} = {\frac{{POd} - {POe}}{POe} \times 100}$

where POd is the concentration of polyolefins in the PET-depletedproduct stream 114 on an undiluted dry weight basis;

POm is the concentration of PO in the MPW feed stream 100 on a dryweight basis; and

POe is the concentration of PO in the PET-enriched product stream 112 ona dry weight basis.

In one embodiment or in combination with any other embodiments, when aMPW stream 100 is fed to the preprocessing facility 20 (or separationzone 22), the PET-depleted stream 114 is also depleted in halogens, suchas fluorine (F), chlorine (Cl), bromine (Br), iodine (I), and astatine(At), and/or halogen-containing compounds, such as PVC, relative to theconcentration or mass of halogens in the MPW stream 100, thePET-enriched stream 112, or both. In one embodiment or in combinationwith any of the mentioned embodiments, the PET-depleted stream 114 has apercent PVC depletion, relative to the MPW feed stream 100 (Feed-Based %PVC Depletion) or the PET-enriched product stream 112 (Product-Based %PVC Depletion) that is at least 1, at least 3, at least 5, at least 7,at least 10, at least 15, at least 20, at least 25, at least 30, atleast 35, at least 40, at least 50, at least 60, at least 65, at least70, at least 75, at least 80, at least 85, or at least 90% as determinedby the formula:

${{Feed} - {Based}\%{PVC}{Depletion}} = {\frac{{PVCm} - {PVCd}}{PVCm} \times 100{and}}$${{Product} - {Based}\%{PVC}{Depletion}} = {\frac{{PVCe} - {PVCd}}{PVCe} \times 100}$

where PVCm is the concentration of PVC in the MPW feed stream 100 on anundiluted dry weight basis;

PVCd is the concentration of PVC in the PET-depleted product stream 114on an undiluted dry weight basis; and

PVCe is the concentration of PVC in the PET-enriched product stream 112on an undiluted dry weight basis.

The PET-depleted stream 114 is depleted in PET relative to theconcentration or mass of PET in the MPW stream 100, the PET-enrichedstream 112, or both. In one embodiment or in combination with any of thementioned embodiments, the PET-depleted stream 114 has a percent PETdepletion, relative to the MPW feed stream 100 (Feed-Base % PETDepletion) or the PET-enriched product stream 112 (Product-Based % PETDepletion) that is at least 1, at least 3, at least 5, at least 7, atleast 10, at least 15, at least 20, at least 25, at least 30, at least35, at least 40, at least 50, at least 60, at least 65, at least 70, atleast 75, at least 80, at least 85, or at least 90% as determined by theformula:

${{Feed} - {Based}\%{PET}{Depletion}} = {\frac{{PETm} - {PETd}}{PETm} \times 100{and}}$${{Product} - {Based}\%{PET}{Depletion}} = {\frac{{PETe} - {PETd}}{PETe} \times 100}$

where PETm is the concentration of PET in the MPW feed stream 100 on anundiluted dry weight basis;

PETd is the concentration of PET in the PET-depleted product stream 114on an undiluted dry weight basis; and

PETe is the concentration of PET in the PET-enriched product stream 112on an undiluted dry weight basis.

The percentage enrichment or depletion in any of the above embodimentscan be an average over 1 week, or over 3 days, or over 1 day, and themeasurements can be conducted to reasonably correlate the samples takenat the exits of the process to MPW bulk from which the sample of MPW istaking into account the residence time of the MPW to flow from entry toexit. For example, if the average residence time of the MPW is 2minutes, then the outlet sample would be taken two minutes after theinput sample, so that the samples correlate to one another.

In an embodiment or in combination with any embodiment mentioned herein,the PET-enriched stream exiting the separation zone 22 or thepreprocessing facility 20 may include at least 50, at least 55, at least60, at least 65, at least 70, at least 75, at least 80, at least 85, atleast 90, at least 95, at least 97, at least 99, at least 99.5, or atleast 99.9 weight percent PET, based on the total weight of plastic inthe PET-enriched stream 112. The PET-enriched stream 112 may also beenriched in PVC and can include, for example, at least 0.1, at least0.5, at least 1, at least 2, at least 3, at least 5 and/or not more than10, not more than 8, not more than 6, not more than 5, not more than 3weight percent of halogens, including PVC, based on the total weight ofplastic in the PET-enriched stream, or it can be in the range of 0.1 toweight percent, 0.5 to 8 weight percent, or 1 to 5 weight percent, basedon the total weight of plastic in the PET-enriched stream. ThePET-enriched stream may include at least 50, at least 55, at least 60,at least 65, at least 70, at least 75, at least 80, at least 85, atleast 90, at least 95, at least 99, or at least 99.5 weight percent ofthe total amount of PET introduced into the preprocessing facility 20(or separation zone 22).

The PET-enriched stream 112 may also be depleted in PO and/or heavierplastics such as polytetrafluoroethylene (PTFE), polyamide (PA 12, PA46, PA 66), polyacrylamide (PARA), polyhydroxybutyrate (PHB),polycarbonate polybutylene terephthalate blends (PC/PBT), polyvinylchloride (PVC), polyimide (PI), polycarbonate (PC), polyethersulfone(PESU), polyether ether ketone (PEEK), polyamide imide (PAI),polyethylenimine (PEI), polysulfone (PSU), polyoxymethylene (POM),polyglycolides (poly(glycolic acid), PGA), polyphenylene sulfide (PPS),thermoplastic styrenic elastomers (TPS), amorphous thermoplasticpolyimide (TPI), liquid crystal polymer (LCP), glass fiber-reinforcedPET, chlorinated polyvinyl chloride (CPVC), polybutylene terephthalate(PBT), polyphthalamide (PPA), polyvinylidene chloride (PVDC), ethylenetetrafluoroethylene (ETFE), polyvinylidene fluoride (PVDF), fluorinatedethylene propylene (FEP), polymonochlorotrifluoroethylene (PCTFE), andperfluoroalkoxy (PFA), any of which may include carbon, glass, and/ormineral fillers, and which have a density higher than PET and PVC.

In an embodiment or in combination with any embodiment mentioned herein,the PET-enriched stream 112 may comprise not more than 45, not more than40, not more than 35, not more than 30, not more than 25, not more than20, not more than 15, not more than 10, not more than 5, not more than2, not more than 1, not more than 0.5 weight percent PO, based on thetotal weight of plastic in the PET-enriched stream 112. The PET-enrichedstream 112 may comprise not more than 10, not more than 8, not more than5, not more than 3, not more than 2, or not more than 1 weight percentof the total amount of PO introduced into the preprocessing facility 20(or separation zone 22). The PET-enriched stream 112 may comprise notmore than 45, not more than 40, not more than 35, not more than 30, notmore than 25, not more than 20, not more than 15, not more than 10, notmore than 5, not more than 2, not more than 1 weight percent ofcomponents other than PET, based on the total weight of the PET-enrichedstream 112.

Additionally, or in the alternative, the PET-enriched stream 112 caninclude not more than 2, not more than 1, not more than 0.5, or not morethan 0.1 weight percent of adhesives on a dry basis. Typical adhesivesinclude carpet glue, latex, styrene butadiene rubber, and the like.Additionally, the PET-enriched stream 112 can include not more than 4,not more than 3, not more than 2, not more than 1, not more than 0.5, ornot more than 0.1 weight percent plastic fillers and solid additives ona dry basis. Exemplary fillers and additives include silicon dioxide,calcium carbonate, talc, silica, glass, glass beads, alumina, and othersolid inerts, which do not chemically react with the plastics or othercomponents in the processes described herein.

In an embodiment or in combination with any embodiment mentioned herein,the PET-depleted (or PO-enriched) stream 114 exiting the separation zone22 or the preprocessing facility 20 may include at least 50, at least55, at least 60, at least 65, at least 70, at least 75, at least 80, atleast 85, at least 90, at least 95, at least 97, at least 99, or atleast 99.5 weight percent PO, based on the total weight of plastic inthe PET-depleted (or PO-enriched) stream 114. The PET-depleted (orPO-enriched stream) may be depleted in PVC and can include, for example,not more than 5, not more than 2, not more than 1, not more than 0.5,not more than 0.1, not more than 0.05, or not more than 0.01 weightpercent of halogens, including chorine in PVC, based on the total weightof plastic in the PET-depleted (or PO-enriched) stream. The PET-depletedor PO-enriched stream may include at least 50, at least 55, at least 60,at least 65, at least 70, at least 75, at least 80, at least 85, atleast 90, at least 95, at least 99, or at least 99.9 weight percent ofthe total amount of PO introduced into the preprocessing facility 20 orseparation facility 22.

The PO-enriched stream 114 may also be depleted in PET and/or otherplastics, including PVC. In an embodiment or in combination with anyembodiment mentioned herein, the PET-depleted (or PO-enriched stream)may comprise not more than 45, not more than 40, not more than 35, notmore than 30, not more than 25, not more than 20, not more than 15, notmore than 10, not more than 5, not more than 2, not more than 1, notmore than 0.5 weight percent PET, based on the total weight of plasticin the PET-depleted or PO-enriched stream. The PO-enriched (orPET-depleted) stream 114 may comprise not more than 10, not more than 8,not more than 5, not more than 3, not more than 2, or not more than 1weight percent of the total amount of PET introduced into thepreprocessing facility.

In an embodiment or in combination with any embodiment mentioned herein,the PET-depleted or PO-enriched stream 114 may also comprise not morethan 45, not more than 40, not more than 35, not more than 30, not morethan 25, not more than 20, not more than 15, not more than 10, not morethan 5, not more than 2, not more than 1 weight percent of componentsother than PO, based on the total weight of PET-depleted or PO-enrichedstream 114. The PET-depleted or PO-enriched stream 114 comprises notmore than 4, not more than 2, not more than 1, not more than 0.5, or notmore than 0.1 weight percent of adhesives, based on the total weight ofthe stream.

In an embodiment or in combination with any embodiment mentioned herein,the PET-depleted or PO-enriched stream 114 may have a melt viscosity ofat least 1, at least 5, at least 50, at least 100, at least 200, atleast 300, at least 400, at least 500, at least 600, at least 700, atleast 800, at least 900, at least 1000, at least 1500, at least 2000, atleast 2500, at least 3000, at least 3500, at least 4000, at least 4500,at least 5000, at least 5500, at least 6000, at least 6500, at least7000, at least 7500, at least 8000, at least 8500, at least 9000, atleast 9500, or at least 10,000 poise, measured using a Brookfield R/Srheometer with V80-40 vane spindle operating at a shear rate of 10 rad/sand a temperature of 350° C. Alternatively, or in addition, thePET-depleted or PO-enriched stream may have a melt viscosity of not morethan 25,000, not more than 24,000, not more than 23,000, not more than22,000, not more than 21,000, not more than 20,000, not more than19,000, not more than 18,000, or not more than 17,000 poise, (measuredat 10 rad/s and 350° C.). Or the stream may have a melt viscosity in therange of from 1 to 25,000 poise, 500 to 22,000 poise, or 1000 to 17,000poise (measured at 10 rad/s and 350° C.).

Any suitable type of separation device, system, or facility may beemployed to separate the waste plastic into two or more streams enrichedin certain types of plastics such as, for example, the PET-enrichedstream 112 and the PO-enriched stream 114. Examples of suitable types ofseparation include mechanical separation and density separation, whichmay include sink-float separation and/or centrifugal density separation.As used herein, the term “sink-float separation” refers to a densityseparation process where the separation of materials is primarily causedby floating or sinking in a selected liquid medium, while the term“centrifugal density separation” refers to a density separation processwhere the separation of materials is primarily caused by centrifugalforces. In general, the term “density separation process” refers to aprocess for separating materials based, at least in part, upon therespective densities of the materials into at least a higher-densityoutput and a lower-density output and includes both sink-floatseparation and centrifugal density separation.

When sink-float separation is used, the liquid medium can comprisewater. Salts, saccharides, and/or other additives can be added to theliquid medium, for example to increase the density of the liquid mediumand adjust the target separation density of the sink-float separationstage. The liquid medium can comprise a concentrated salt solution. Inone or more such embodiments, the salt is sodium chloride. In one ormore other embodiments, however, the salt is a non-halogenated salt,such as acetates, carbonates, citrates, nitrates, nitrites, phosphates,and/or sulfates. The liquid medium can comprise a concentrated saltsolution comprising sodium bromide, sodium dihydrogen phosphate, sodiumhydroxide, sodium iodide, sodium nitrate, sodium thiosulfate, potassiumacetate, potassium bromide, potassium carbonate, potassium hydroxide,potassium iodide, calcium chloride, cesium chloride, iron chloride,strontium chloride, zinc chloride, manganese sulfate, magnesium sulfate,zinc sulfate, and/or silver nitrate. In an embodiment or in combinationwith any embodiment mentioned herein, the salt is a caustic component.The salt may comprise sodium hydroxide, potassium hydroxide, and/orpotassium carbonate. The concentrated salt solution may have a pH ofgreater than 7, greater than 8, greater than 9, or greater than 10.

In an embodiment or in combination with any embodiment mentioned herein,the liquid medium can comprise a saccharide, such as sucrose. The liquidmedium can comprise carbon tetrachloride, chloroform, dichlorobenzene,dimethyl sulfate, and/or trichloro ethylene. The particular componentsand concentrations of the liquid medium may be selected depending on thedesired target separation density of the separation stage. Thecentrifugal density separation process may also utilize a liquid mediumas described above to improve separation efficiency at the targetseparation density.

In an embodiment or in combination with any embodiment mentioned herein,the waste plastic separation methods comprise at least two densityseparation stages. In certain such embodiments, the methods generallycomprise introducing waste plastic particulates into the first densityseparation stage and feeding an output from the first density separationstage into the second density separation stage. The density separationstages can be any system or unit operation that performs a densityseparation process, as defined herein. At least one of the densityseparation stages comprises a centrifugal force separation stage or asink-float separation stage. Each of the first and second densityseparation stages comprises a centrifugal force separation stage and/ora sink-float separation stage.

To produce a PET-enriched material stream, one of the density separationstages may comprise a low-density separation stage and the othergenerally comprises a high-density separation stage. As defined herein,the low-density separation stage has a target separation density lessthan the target separation density of the high-density separation stage.The low-density separation stage has a target separation density lessthan the density of PET, and the high-density separation stage has atarget separation density greater than the density of PET.

As used herein, the term “target separation density” refers to a densityabove which materials subjected to a density separation process arepreferentially separated into the higher-density output and below whichmaterials are separated in the lower-density output. The targetseparation density specifies a density value, wherein it is intendedthat all plastics and other solid materials having a density higher thanthe value are separated into the higher-density output and all plasticsand other solid materials having a density lower than the value areseparated into the lower-density output. However, the actual separationefficiency of the materials in a density separation process may dependon various factors, including residence time and relative closeness ofthe density of a particular material to the target density separationvalue, as well as factors related to the form of the particulate suchas, for example, area-to-mass ratio, degree of sphericity, and porosity.

In an embodiment or in combination with any embodiment mentioned herein,the low-density separation stage has a target separation density that isless than 1.35, less than 1.34, less than 1.33, less than 1.32, lessthan 1.31, or less than 1.30 g/cc and/or at least 1.25, at least 1.26,at least 1.27, at least 1.28, or at least 1.29 g/cc. The high-densityseparation stage has a target separation density that is at least 0.01,at least 0.025, at least 0.05, at least 0.075, at least 0.1, at least0.15, or at least 0.2 g/cc greater than the target separation density ofthe low-density separation stage. The target separation density of thehigh-density separation stage is at least 1.31, at least 1.32, at least1.33, at least 1.34, at least 1.35, at least 1.36, at least 1.37, atleast 1.38, at least 1.39, or at least 1.40 g/cc and/or not more than1.45, not more than 1.44, not more than 1.43, not more than 1.42, or notmore than 1.41 g/cc. The target separation density of the low-densityseparation stage is in the range of 1.25 to 1.35 g/cc and the targetseparation density of said high-density separation stage is in the rangeof 1.35 to 1.45 g/cc.

Referring again to FIG. 1 , both the PET-enriched stream 112 and thePO-enriched stream 114 may be introduced into one or more downstreamprocessing facilities (or undergo one or more downstream processingsteps) within the chemical recycling facility 10. In an embodiment or incombination with any embodiment mentioned herein, at least a portion ofthe PET-enriched stream 112 may be introduced into a solvolysis facility30, while at least a portion of the PO-enriched stream 114 may bedirectly or indirectly introduced into one or more of a pyrolysisfacility 60, a cracking facility 70, a partial oxidation (POX)gasification facility 50, an energy recovery facility 80, or otherfacility 90, such as a solidification or separation facility. Additionaldetails of each step and type of facility, as well as the generalintegration of each of these steps or facilities with one or more of theothers according to one or more embodiments of the present technologyare discussed in further detail below.

Solvolysis

In an embodiment or in combination with any embodiment mentioned herein,at least a portion of a PET-enriched stream 112 from the preprocessingfacility 20 may be introduced into a solvolysis facility 30. As usedherein, the term “solvolysis” or “ester solvolysis” refers to a reactionby which an ester-containing feed is chemically decomposed in thepresence of a solvent to form a principal carboxyl product and aprincipal glycol product. A “solvolysis facility” is a facility thatincludes all equipment, lines, and controls necessary to carry outsolvolysis of waste plastic and feedstocks derived therefrom.

When the ester being subjected to solvolysis comprises PET, thesolvolysis performed in the solvolysis facility may be PET solvolysis.As used herein, the term “PET solvolysis” refers to a reaction by whicha polyester terephthalate-containing feed is chemically decomposed inthe presence of a solvent to form a principal terephthalyl product and aprincipal glycol product. As used herein, the term “principalterephthalyl” refers to the main or key terephthalyl product beingrecovered from the solvolysis facility. As used herein, the term“principal glycol” refers to the main glycol product being recoveredfrom the solvolysis facility. As used herein, the term “glycol” refersto a component comprising two or more —OH functional groups permolecule. As used herein, the term “terephthalyl” refers to a moleculeincluding the following group:

In an embodiment or in combination with any embodiment mentioned herein,the principal terephthalyl product comprises a terephthalyl, such asterephthalic acid or dimethyl terephthalate (or oligomers thereof),while the principal glycol comprises a glycol, such as ethylene glycoland/or diethylene glycol. The main steps of a PET solvolysis facility 30according to one or more embodiments of the present technology aregenerally shown in FIG. 3 .

In an embodiment or in combination with any embodiment mentioned herein,the principal solvent used in solvolysis comprises a chemical compoundhaving at least one —OH group. Examples of suitable solvents caninclude, but are not limited to, (i) water (in which case the solvolysismay be referred to as “hydrolysis”), (ii) alcohols (in which case thesolvolysis may be referred to as “alcoholysis”), such as methanol (inwhich case the solvolysis may be referred to as “methanolysis”) orethanol (in which case the solvolysis may be referred to as“ethanolysis”), (iii) glycols such as ethylene glycol or diethyleneglycol (in which case the solvolysis may be referred to as“glycolysis”), or (iv) ammonia (in which case the solvolysis may bereferred to as “ammonolysis”).

In an embodiment or in combination with any embodiment mentioned herein,the solvolysis solvent can include at least 50, at least 55, at least60, at least 65, at least 70, at least 75, at least 80, at least 85, atleast 90, at least 95, at least or at least 99 weight percent of theprincipal solvent, based on the total weight of the solvent stream. Inan embodiment or in combination with any embodiment mentioned herein,the solvent may comprise not more than 45, not more than 40, not morethan 35, not more than 30, not more than 25, not more than 20, not morethan 15, not more than 10, not more than 5, not more than 2, or not morethan 1 weight percent of other solvents or components, based on thetotal weight of the solvent stream.

When the solvolysis facility 30 utilizes a glycol, such as ethyleneglycol, as the principal solvent, the facility may be referred to as aglycolysis facility. In an embodiment or in combination with anyembodiment mentioned herein, the chemical recycling facility of FIG. 1may comprise a glycolysis facility. In a glycolysis facility, PET can bechemically decomposed to form ethylene glycol (EG) as the principalglycol and dimethyl terephthalate (DMT) as the principal terephthalyl.When the PET comprises waste plastic, both the EG and DMT formed in thesolvolysis facility may comprise recycle content ethylene glycol (r-EG)and recycle content dimethyl terephthalate (r-DMT). When formed byglycolysis, the EG and DMT can be present in a single product stream.

When a solvolysis facility utilizes methanol as the principal solvent,the facility may be referred to as a methanolysis facility. The chemicalrecycling facility of FIG. 1 may include a methanolysis facility. In amethanolysis facility, an example of which is schematically depicted inFIG. 3 , PET can be chemically decomposed to form ethylene glycol (EG)as the principal glycol and dimethyl terephthalate (DMT) as theprincipal terephthalyl. When the PET comprises waste plastic, both theEG and DMT formed in the solvolysis facility may comprise recyclecontent ethylene glycol (r-EG) and recycle content dimethylterephthalate (r-DMT).

In an embodiment or in combination with any embodiment mentioned herein,the stream of recycle content glycol 154 (r-glycol) withdrawn from thesolvolysis facility 30 may comprise at least 45, at least 50, at least55, at least 60, at least 65, at least 70, at least 75, at least 80, atleast 85, at least 90, or at least 95 weight percent of the principalglycol formed in the solvolysis facility. It may also include not morethan 99.9, not more than 99, not more than 95, not more than 90, notmore than 85, not more than 80, or not more than 75 weight percent ofthe principal glycol (such as EG), and/or may include at least 0.5, atleast 1, at least 2, at least 5, at least 7, at least 10, at least 12,at least 15, at least 20, or at least 25 weight percent and/or not morethan 45, not more than 40, not more than 35, not more than 30, not morethan 25, not more than 20, or not more than 15 weight percent ofcomponents other than the principal glycol, based on the total weight ofthe stream, or these may be present in amounts in the range of from 0.5to 45 weight percent, 1 to 40 weight percent, or 2 to 15 weight percent,based on the total weight of the stream. The r-glycol may be present inthe stream 154 in an amount in the range of from 45 to 99.9 weightpercent, 55 to 99.9 weight percent, or 80 to 99.9 weight percent, basedon the total weight of the stream 154.

In an embodiment or in combination with any embodiment mentioned herein,the stream of recycle content principal terephthalyl (r-terephthalyl)158 withdrawn from the solvolysis facility may comprise at least 45, atleast 50, at least 55, at least 60, at least 65, at least 70, at least75, at least 80, at least 85, at least 90, or at least 95 weight percentof the principal terephthalyl (such as DMT) formed in the solvolysisfacility 30. It may also include not more than 99, not more than 95, notmore than 90, not more than 85, not more than 80, or not more than 75weight percent of the principal terephthalyl, or the principalterephthalyl may be present in an amount of 45 to 99 weight percent, 50to 90 weight percent, or 55 to 90 weight percent, based on the totalweight of the stream. Additionally, or in the alternative, the streamcan include at least 0.5, at least 1, at least 2, at least 5, at least7, at least 10, at least 12, at least 15, at least 20, or at least 25weight percent and/or not more than 45, not more than 40, not more than35, not more than 30, not more than 25, not more than 20, or not morethan 15 weight percent of components other than the principalterephthalyl, based on the total weight of the stream. Ther-terephthalyl (or terephthalyl) may be present in the stream 154 in anamount in the range of from 45 to 99.9 weight percent, 55 to 99.9 weightpercent, or 80 to 99.9 weight percent, based on the total weight of thestream 154.

In addition to providing a recycle content principal glycol stream, arecycle content principal terephthalyl stream, the solvolysis facilitymay also provide one or more solvolysis coproduct streams, shown asstream 110 in FIG. 1 , which may also be withdrawn from one or morelocations within the solvolysis facility. As used herein, the term“coproduct” or “solvolysis coproduct” refers to any compound from asolvolysis facility that is not the principal carboxyl (terephthalyl)product of the solvolysis facility, the principal glycol product of thesolvolysis facility, or the principal solvent fed to the solvolysisfacility. Solvolysis coproduct streams can comprise at least 40, atleast 45, at least 50, at least 55, at least 60, at least 65, at least70, at least 75, at least 80, at least 85, at least 90, at least 95, orat least 99 weight percent of one or more solvolysis coproducts, basedon the total weight of the stream.

Solvolysis coproducts can comprise a heavy organic solvolysis coproductstream or a light organic solvolysis coproduct stream. As used herein,the term “heavy organic solvolysis coproduct” refers to a solvolysiscoproduct with a boiling point higher than the boiling point of theprincipal terephthalyl product of the solvolysis facility, while theterm “light organics solvolysis coproduct” refers to a solvolysiscoproduct with a boiling point lower than the boiling point of theprincipal terephthalyl product of the solvolysis facility.

When the solvolysis facility is a methanolysis facility, one or moremethanolysis coproducts may be withdrawn from the facility. As usedherein, the term “methanolysis coproduct” refers to any compound from amethanolysis facility that is not DMT, EG, or methanol. Methanolysiscoproduct streams can comprise at least 40, at least 45, at least 50, atleast 55, at least 60, at least 65, at least 70, at least 75, at least80, at least 85, at least 90, at least 95, or at least 99 weight percentof one or more solvolysis coproducts, based on the total weight of thestream. In an embodiment or in combination with any embodiment mentionedherein, methanolysis coproduct streams can comprise a heavy organicmethanolysis coproduct or light organic methanolysis coproduct. As usedherein, the term “heavy organic methanolysis coproduct” refers to amethanolysis coproduct with a boiling point greater than DMT, while theterm “light methanolysis coproduct” refers to a methanolysis coproductwith a boiling point less than DMT.

In an embodiment or in combination with any embodiment mentioned herein,the solvolysis facility may produce at least one heavy organicsolvolysis coproduct stream. The heavy organic solvolysis coproductstream may include at least 40, at least 45, at least 50, at least 55,at least 60, at least 65, at least 70, at least 75, at least 80, atleast 85, at least 90, or at least 95 weight percent of organiccompounds having a boiling point higher than the boiling point of theprincipal terephthalyl (such as DMT) produced from the solvolysisfacility 30, based on the total weight of organics in the stream.

Additionally, or in the alternative, the solvolysis facility may produceat least one light organics solvolysis coproduct stream. The lightorganics solvolysis coproduct stream may include at least 40, at least45, at least 50, at least 55, at least 60, at least 65, at least 70, atleast 75, at least 80, at least 85, at least 90, or at least 95 weightpercent of organic compounds having a boiling point lower than theboiling point of the principal terephthalyl (such as DMT) produced fromthe solvolysis facility 30, based on the total weight of organics in thestream.

Turning again to FIG. 3 , in operation, streams of mixed plastic wasteand solvent introduced (separately or together) into the solvolysisfacility may first be passed through an optional non-PET separation zone208, wherein at least 50, at least 55, at least 60, at least 65, atleast 70, at least 75, at least 80, at least 85, at least 90, or atleast 95 weight percent of the total weight of components other than PETare separated out. The non-PET components may have a boiling point lowerthan PET and may be removed from the zone 208 as a vapor. Alternatively,or in addition, at least a portion of the non-PET components may have aslightly higher or lower density than PET and may be separated out byforming a two-phase liquid stream, then removing one or both non-PETphases. Finally, in some embodiments, the non-PET components may beseparated out as solids from a PET-containing liquid phase.

In an embodiment or in combination with any embodiment mentioned herein,at least 50, at least 55, at least 60, at least 65, at least 70, atleast 75, at least 80, at least 85, at least 90, or at least 95 percentof the non-PET components separated from the PET-containing streamcomprise polyolefins such as polyethylene and/or polypropylene. Asindicated generally by the dashed lines in FIG. 3 , all or a part of thenon-PET separation zone 208 may be upstream of the reaction zone 210,while all or a part of the non-PET separation zone 208 may be downstreamof the reaction zone 210. Separation techniques such as extraction,solid/liquid separation, decanting, cyclone or centrifugal separation,manual removal, magnetic removal, eddy current removal, chemicaldegradation, vaporization and degassing, distillation, and combinationsthereof may be used to separate the non-PET components from thePET-containing stream in the non-PET separation zone 208.

As shown in FIG. 3 , the PET-containing stream 138 exiting the non-PETseparation zone 208 may comprise not more than 25, not more than 20, notmore than 15, not more than 10, not more than 5, not more than 2, notmore than 1, or not more than 0.5 weight percent of components otherthan the PET (or its oligomeric and monomeric degradation products) andsolvent, based on the total weight of the PET-containing stream. ThePET-containing stream 138 exiting the non-PET separation zone 208 maycomprise not more than 25, not more than 20, not more than 15, not morethan 10, not more than 5, not more than 2, or not more than 1 weightpercent of other types of plastics (such as polyolefins). ThePET-containing stream 138 exiting the non-PET separation zone 208 mayinclude not more than 45, not more than 40, not more than 35, not morethan 30, not more than 25, not more than 20, not more than 10, not morethan 5, or not more than 2 weight percent of the total amount of non-PETcomponents introduced into the non-PET separation zone 208.

The non-PET components may be removed from the solvolysis (ormethanolysis) facility 30 as generally shown in FIG. 3 as apolyolefin-containing coproduct stream 140. The polyolefin-containingcoproduct stream (or decanter olefin coproduct stream) 140 may compriseat least 35, at least 40, at least 45, at least 50, at least 55, atleast 60, at least 65, at least 70, at least 75, at least 80, at least85, at least 90, at least 92, at least 95, at least 97, at least 99, orat least 99.5 weight percent of polyolefin, based on the total weight ofthe coproduct stream 140.

The polyolefin present in the polyolefin-containing coproduct stream maycomprise predominantly polyethylene, predominantly polypropylene, or acombination of polyethylene and polypropylene. The polyolefin in thepolyolefin-containing coproduct stream comprises at least 70, at least75, at least 80, at least 85, at least 90, at least 92, at least 94, atleast 95, at least 97, at least 98, or at least 99 weight percent ofpolyethylene, based on the total weight of the polyolefin in thepolyolefin-containing coproduct stream 140. Alternatively, thepolyolefin in the polyolefin-containing coproduct stream comprises atleast 70, at least 75, at least 80, at least 85, at least 90, at least92, at least 94, at least 95, at least 97, at least 98, or at least 99weight percent of polypropylene, based on the total weight of thepolyolefin in the polyolefin-containing coproduct stream 140.

The polyolefin-containing coproduct stream comprises not more than 10,not more than 5, not more than 2, not more than 1, not more than 0.75,not more than 0.50, not more than 0.25, not more than 0.10, or not morethan 0.05 weight percent of PET, based on the total weight of thepolyolefin-containing coproduct stream 140. Additionally, thepolyolefin-containing coproduct stream comprises at least 0.01, at least0.05, at least 0.10, at least 0.50, at least 1, or at least 1.5 and/ornot more than 40, not more than 35, not more than 30, not more than 25,not more than 20, not more than 15, not more than 10, not more than 5,or not more than 2 weight percent of components other than polyolefin,based on the total weight of the polyolefin-containing coproduct stream140.

Overall, the polyolefin-containing coproduct stream 140 comprises atleast 40, at least 45, at least 50, at least 55, at least 60, at least65, at least 70, at least 75, at least 80, at least 85, at least 90, atleast 95, or at least 99 weight percent of organic compounds, based onthe total weight of the polyolefin-containing coproduct stream 140. Thepolyolefin-containing coproduct stream 140 can include at least 0.5, atleast 1, at least 2, at least 3, at least 5, at least 10, or at least 15and/or not more than 40, not more than 35, not more than 30, not morethan 25, not more than 20, not more than 15, not more than 10, not morethan 5, not more than 2, or not more than 1 weight percent of inorganiccomponents, based on the total weight of the polyolefin-containingcoproduct stream 140.

The polyolefin-containing coproduct stream can comprise at least 0.1, atleast 0.5, at least 1, at least 1.5, at least 2, at least 2.5, at least3, at least 3.5, at least 4, at least 4.5, at least 5, at least 8, atleast 10, at least 12, at least 15, at least 18, at least 20, at least22, or at least 25 weight percent and/or not more than 50, not more than45, not more than 40, not more than 35, not more than 30, not more than25, not more than 20, not more than 15, not more than 10, not more than5, or not more than 2 weight percent of one or more non-reactive solids,based on the total weight of the polyolefin-containing coproduct stream140. Non-reactive solids refer to solid components that do notchemically react with PET. Examples of non-reactive solids include, butare not limited to, sand, dirt, glass, plastic fillers, and combinationsthereof.

The polyolefin-containing coproduct stream 140 comprises at least 100,at least 250, at least 500, at least 750, at least 1000, at least 1500,at least 2000, at least 2500, at least 5000, at least 7500 ppm by weightor at least 1, at least 1.5, at least 2, at least 5, at least 10, atleast 15, at least 20, or at least 25 weight percent) and/or not morethan 50, not more than 45, not more than 40, not more than 35, not morethan 30, not more than 25, not more than 20, not more than 15, not morethan 10, not more than 5, not more than 2, or not more than 1 weightpercent of one or more fillers, based on the total weight of thepolyolefin-coproduct stream 140. The polyolefin-containing coproductstream 140 can include fillers in an amount of 100 ppm to 50 weightpercent, 500 ppm to 10 weight percent, or 1000 ppm to 5 weight percent.

Examples of fillers can include, but are not limited to, thixotropicagents such as fumes silica and clay (kaolin), pigments, colorants, fireretardants such as alumina trihydrate, bromine, chlorine, borate, andphosphorous, suppressants such as wax based materials, UV inhibitors orstabilizers, conductive additives such as metal particles, carbonparticles, or conductive fibers, release agents such as zinc stearate,waxes, and silicones, calcium carbonate, and calcium sulfate.

In an embodiment or in combination with any embodiment mentioned herein,the polyolefin-containing coproduct stream 140 can have a density of atleast 0.75, at least 0.80, at least 0.85, at least 0.90, at least 0.95,at least 0.99 and/or not more than 1.5, not more than 1.4, not more than1.3, not more than 1.2, not more than 1.1, not more than 1.05, or notmore than 1.01 g/cm³, measured at a temperature of 25° C. The densitycan be from 0.80 to 1.4, from 0.90 to 1.2, or 0.95 to 1.1 g/cm³. Whenremoved from the non-PET separation zone 208, the polyolefin-containingcoproduct stream 140 may have a temperature of at least 200, at least205, at least 210, at least 215, at least 220, at least 225, at least230, or at least 235° C. and/or not more than 350, not more than 340,not more than 335, not more than 330, not more than 325, not more than320, not more than 315, not more than 310, not more than 305, or notmore than 300° C. The polyolefin-containing coproduct stream 140 cancomprise at least 50, at least 55, at least 60, at least 65, at least70, at least 75, at least 80, at least 85, at least 90, or at least 95weight percent of components boiling higher than the principalterephthalyl or DMT, based on the total weight of the stream.

As discussed in further detail herein, all or a portion of thepolyolefin-containing coproduct stream may be introduced into one ormore downstream chemical recycling facilities alone or in combinationwith one or more other coproduct streams, streams resulting from one ormore of the other downstream chemical recycling facilities, and/orstreams of waste plastic, including mixed plastic waste that isunprocessed, partially processed, and/or processed.

Turning again to FIG. 3 , the PET-containing stream 138 (which comprisesdissolved PET as well as its degradation products) exiting the non-PETseparation zone 208 (upstream of the reaction zone 210) may then betransferred to a reaction zone 210, wherein at least 50, at least 55, atleast 60, at least 65, at least 70, at least 75, at least 80, at least85, at least 90, or at least 95 percent of the decomposition of the PETintroduced into the reaction zone occurs. In some embodiments, thereaction medium within reaction zone 210 may be agitated or stirred andone or more temperature control devices (such as heat exchangers) may beemployed to maintain a target reaction temperature. In an embodiment orin combination with any embodiment mentioned herein, the target reactiontemperature in the reaction zone 210 can be at least 50, at least 55, atleast 60, at least 65, at least 70, at least 75, at least 80, or atleast 85° C. and/or not more than 350, not more than 345, not more than340, not more than 335, not more than 330, not more than 325, not morethan 320, not more than 315, not more than 310, not more than 300, ornot more than 295° C.

In an embodiment or in combination with any embodiment mentioned herein,the solvolysis process can be a low-pressure solvolysis process and thepressure in the solvolysis reactor (or reaction zone) 210 can be within5, within 10, within 15, within 20, within 25, within 30, within 35,within 40, within 45, or within 50 psi of atmospheric, or it may bewithin 55, within 75, within 90, within 100, within 125, within 150,within 200, or within 250 psi of atmospheric. The pressure in thesolvolysis reactor (or reaction zone) 210 can be within 0.35, within0.70, within 1, within 1.4, within 1.75, within 2, within 2.5, within2.75, within 3, within 3.5, within 3.75, within 5, or within 6.25 bargauge (bar) and/or not more than 6.9, not more than 8.6, or not morethan 10.35 bar of atmospheric. The pressure in the solvolysis reactor(or reaction zone) 210 can be at least 100 psig (6.7 barg), at least 150psig (10.3 barg), at least 200 psig (13.8 barg), at least 250 psig (17.2barg), at least 300 psig (20.7 barg), at least 350 psig (24.1 barg), atleast 400 psig (27.5 barg) and/or not more than 725 psig (50 barg), notmore than 650 psig (44.7 barg), not more than 600 psig (41.3 barg), notmore than 550 psig (37.8 barg), not more than 500 psig (34.5 barg), notmore than 450 psig (31 barg), not more than 400 psig (27.6 barg), or notmore than 350 psig (24.1 barg).

In an embodiment or in combination with any embodiment mentioned herein,the solvolysis process carried out in reaction zone 210 or facility 30can be a high-pressure solvolysis process and the pressure in thesolvolysis reactor can be at least 50 barg (725 psig), at least 70 barg(1015 psig), at least 75 barg (1088 psig), at least 80 barg (1161 psig),at least 85 barg (1233 psig), at least 90 barg (1307 psig), at least 95barg (1378 psig), at least 100 barg (1451 psig), at least 110 barg (1596psig), at least 120 barg (1741 psig), or at least 125 barg (1814 psig)and/or not more than 150 barg (2177 barg), not more than 145 barg (2104psig), not more than 140 barg (2032 psig), not more than 135 barg (1959psig), not more than 130 barg (1886 psig), or not more than 125 barg(1814 psig).

In an embodiment or in combination with any embodiment mentioned herein,the average residence time of the reaction medium in the reaction zone210 can be at least 1, at least 2, at least 5, at least 10, or at least15 minutes and/or not more than 12, not more than 11, not more than 10,not more than 9, not more than 8, not more than 7, not more than 6, notmore than 5, or not more than 4 hours. At least 50, at least 55, atleast 60, at least 65, at least 70, at least 75, at least 80, at least85, at least 90, at least 95, or at least 99 percent of the total weightof PET introduced into the solvolysis or methanolysis facility can bedecomposed upon leaving the reaction zone 210 in the reactor effluentstream 144.

In an embodiment or in combination with any embodiment mentioned herein,a reactor purge stream 142 may be removed from the reaction zone 210 andat least a portion may be passed to one or more downstream facilitieswithin the chemical recycling facility 10 as a reactor purge coproductstream 142. The reactor purge coproduct stream 142 may have a boilingpoint higher than the boiling point of the principal terephthalyl (orDMT in the case or methanolysis) produced from the solvolysis facility30.

In an embodiment or in combination with any embodiment mentioned herein,the reactor purge coproduct stream 142 comprises at least 25, at least30, at least 35, at least 40, at least 45, at least 50, at least 55, atleast 60, at least 65, at least 70, at least 75, at least 80, at least85, at least 90, at least 95, or at least 99 weight percent of theprincipal terephthalyl, based on the total weight of the stream 142.When the solvolysis facility is a methanolysis facility, the reactorpurge coproduct stream 142 may comprise at least 1, at least 5, at least10, at least 15, at least 20, at least 25, at least 30, at least 35, atleast 40, at least 45, at least 50, at least 55, at least 60, at least65, at least 70, at least 75, at least 80, at least 85, at least 90, atleast 95, or at least 99 weight percent of DMT, based on the totalweight of the stream 142.

In addition, the reactor purge coproduct stream 142 may include at least100 ppm and not more than 25 weight percent of one or morenon-terephthalyl solids, based on the total weight of the stream 142. Inan embodiment or in combination with any embodiment mentioned herein,the total amount of non-terephthalyl solids in the reactor purgecoproduct stream 142 can be at least 150, at least 200, at least 250, atleast 300, at least 350, at least 400, at least 500, at least 600, atleast 700, at least 800, at least 900, at least 1000, at least 1500, atleast 2000, at least 2500, at least 3000, at least 3500, at least 4000,at least 4500, at least 5000, at least 5500, at least 6000, at least7000, at least 8000, at least 9000, at least 10,000, or at least 12,500ppm and/or not more than 25, not more than 22, not more than 20, notmore than 18, not more than 15, not more than 12, not more than 10, notmore than 8, not more than 5, not more than 3, not more than 2, or notmore than 1 weight percent, based on the total weight of the stream.

In an embodiment or in combination with any embodiment mentioned herein,the reactor purge coproduct stream 142 has a total solids content of atleast 100, at least 250, at least 500, at least 750, at least 1000, atleast 1500, at least 2000, at least 2500, at least 3000, at least 3500,at least 4000, at least 4500, at least 5000, at least 5500, at least6000, at least 6500, at least 7000, at least 7500, at least 8000, atleast 8500, at least 9000, at least 9500 ppm by weight or at least 1, atleast 2, at least 5, at least 8, at least 10, or at least 12 weightpercent and/or not more than 25, not more than 22, not more than 20, notmore than 17, not more than 15, not more than 12, not more than 10, notmore than 8, not more than 6, not more than 5, not more than 3, not morethan 2, or not more than 1 weight percent or not more than 7500, notmore than 5000, or not more than 2500 ppm by weight, based on the totalweight of the stream.

Examples of solids can include, but are not limited to, non-volatilecatalyst compounds. In an embodiment or in combination with anyembodiment mentioned herein, the reactor purge coproduct stream caninclude at least 100, at least 250, at least 500, at least 750, at least1000, at least 1500, at least 2000, at least 2500, at least 3000, atleast 3500, at least 4000, at least 4500, at least 5000, at least 7500,at least 10,000, or at least 12,500 ppm and/or not more than 60,000, notmore than 50,000, not more than 40,000, not more than 35,000, not morethan 30,000, not more than 25,000, not more than 20,000, not more than15,000, or not more than 10,000 ppm of non-volatile catalyst metals.

Examples of suitable non-volatile catalyst metals can include, but arenot limited to, titanium, zinc, manganese, lithium, magnesium, sodium,methoxide, alkali metals, alkaline earth metals, tin, residualesterification or ester exchange catalysts, residual polycondensationcatalysts, aluminum, depolymerization catalysts, and combinationsthereof. As discussed in further detail herein, all or a portion of thereactor purge coproduct stream 142 may be introduced into one or moredownstream chemical recycling facilities alone or in combination withone or more other coproduct streams, streams resulting from one or moreof the other downstream chemical recycling facilities, and/or streams ofwaste plastic, including mixed plastic waste that is unprocessed,partially processed, and/or processed.

In an embodiment or in combination with any embodiment mentioned herein,as generally shown in FIG. 3 , the effluent stream 144 from the reactionzone 210 in a solvolysis facility 30 may optionally be sent through anon-PET separation zone 208 located downstream of the reactor, asdiscussed previously. The resulting effluent stream 144 from the reactoror, when present, the non-PET separation zone 208, may be passed througha product separation zone 220, wherein at least 50, at least 55, atleast 60, at least 65, at least 70, at least 75, at least 80, at least85, at least 90, at least 95, or at least 99 weight percent of the heavyorganic materials are separated from the feed stream 144 to form streamsof predominantly light organic materials 146 and heavy organic materials148. Any suitable method of separating such streams can be used and mayinclude, for example, distillation, extraction, decanting,crystallization, membrane separation, solid/liquid separation such as,for example, filtration (e.g., a belt filter), and combinations thereof.

As shown in FIG. 3 , the heavy organic stream 148 withdrawn from theproduct separation zone 220, which may include for example at least 55,at least 60, at least 65, at least 70, at least 75, at least 80, atleast 85, at least 90, at least 95, or at least 99 weight percent ofheavy organic components, based on the total weight of the stream, maybe introduced into a heavy organics separation zone 240. In the heavyorganics separation zone 240, a primary terephthalyl product stream 158may be separated from a terephthalyl bottoms or “sludge” coproductstream 160. Such separation may be accomplished by, for example,distillation, extraction, decantation, membrane separation, meltcrystallization, zone refining, and combinations thereof. The result isa stream 158 comprising at least 50, at least 55, at least 60, at least65, at least 70, at least 75, at least 80, at least 85, at least 90, atleast 95, or at least 99 weight percent of the principal terephthalyl(or DMT), based on the total weight of the stream. In an embodiment orin combination with any embodiment mentioned herein, at least a portionor all of the primary terephthalyl can comprise recycle contentterephthalyl (r-terephthalyl), such as recycle content DMT (r-DMT).

Also withdrawn from the heavy organics separation zone 240 is aterephthalyl bottoms coproduct stream (also called “terephthalyl columnbottoms coproduct stream” or “terephthalyl sludge coproduct stream” or“terephthalyl dregs coproduct stream”) coproduct stream 160 may also beremoved from the heavy organics separation zone 240. When the solvolysisfacility is a methanolysis facility, the stream can be referred to as aDMT bottoms coproduct stream, a DMT column bottoms coproduct stream, aDMT sludge coproduct stream, or a DMT dregs stream.

In an embodiment or in combination with any embodiment mentioned herein,this coproduct stream can include, for example, at least 60, at least65, at least 70, at least 75, at least 80, at least 85, at least 90, atleast 92, at least 95, at least 97, at least 98, at least 99, or atleast 99.5 weight percent of oligomers comprising moieties of thepolyester undergoing solvolysis, based on the total weight of thecomposition such as, for example, PET oligomers. As used herein, theterms “polyester moieties” or “moieties of polyester,” refer to portionsor residues of a polyester, or reaction products of the polyesterportions or residues. These oligomers can have a number average chainlength of at least 2, at least 3, at least 4, at least 5, at least 6, atleast 7, or at least 8 monomer units (acid+glycol) and/or not more than30, not more than 27, not more than 25, not more than 22, not more than20, not more than 17, not more than 15, not more than 12, or not morethan 10 monomer units (acid+glycol) and may include moieties of thepolyester being processed (e.g., PET).

In an embodiment or in combination with any embodiment mentioned herein,the terephthalyl column bottoms (or the DMT column bottoms) coproductstream 160 may comprise oligomers and at least one substitutedterephthalyl component. As used herein, the term “substitutedterephthalyl” refers to a terephthalyl component having at least onesubstituted atom or group. The terephthalyl column bottoms coproductstream 160 can include at least 1, at least 100, at least 500 parts perbillion by weight, or at least 1, at least 50, at least 1000, at least2500, at least 5000, at least 7500, or at least 10,000 parts per millionby weight, or at least 1, at least 2, or at least 5 weight percentand/or not more than 25, not more than 20, not more than 15, not morethan 10, not more than 5, not more than 2, not more than 1, not morethan 0.5, not more than 0.1, not more than 0.05, or not more than 0.01weight percent of substituted terephthalyl components, based on thetotal weight of the terephthalyl column bottoms coproduct stream 160.

As discussed in further detail herein, all or a portion of theterephthalyl column bottoms coproduct stream 160 may be introduced intoone or more downstream chemical recycling facilities alone or incombination with one or more other coproduct streams, streams resultingfrom one or more of the other downstream chemical recycling facilities,and/or streams of waste plastic, including mixed plastic waste that isunprocessed, partially processed, and/or processed.

Referring again to FIG. 3 , the predominantly light organics stream 146from the product separation zone 220 may be introduced into a lightorganics separation zone 230. In the light organics separation zone 230,the stream 146 may be separated to remove the principal solvent (e.g.,methanol in methanolysis) and to separate out the principal glycol(e.g., ethylene glycol in methanolysis) from an organic coproduct (orcoproducts) lighter than and heavier than the principal glycol.

In an embodiment or in combination with any embodiment mentioned herein,a solvent stream 150 withdrawn from the light organics separation zone230 can include at least 50, at least 55, at least 60, at least 65, atleast 70, at least 75, at least 80, at least 85, at least 90, at least95, or at least 99 weight percent of the principal solvent, based on thetotal weight of the stream 150. When the solvolysis facility 30 is amethanolysis facility, this stream 150 may comprise at least 50, atleast 55, at least 60, at least 65, at least 70, at least 75, at least80, at least 85, at least 90, at least 95, or at least 99 weight percentof methanol, based on the total weight of the stream. All or a portionof the stream may be recycled back to one or more locations within thesolvolysis facility for further use.

In an embodiment or in combination with any embodiment mentioned herein,at least one light organics solvolysis coproduct stream 152 (alsoreferred to as a “light organics” stream) can also be withdrawn from thelight organics separation zone 230 and may include at least 40, at least45, at least 50, at least 55, at least 60, at least 65, at least 70, atleast 75, at least 80, at least 85, at least 90, or at least 95 weightpercent of components with a boiling point lower than the boiling pointof the principal terephthalyl (or DMT) that are not the principal glycol(or ethylene glycol) or the principal solvent (or methanol).Additionally, or in the alternative, the coproduct stream can comprisenot more than 60, not more than 55, not more than 50, not more than 45,not more than 40, not more than 35, not more than 30, not more than 25,not more than 20, not more than 15, not more than 10, not more than 5,not more than 3, not more than 2, not more than 1 weight percent ofcomponents with a boiling point higher than the boiling point of DMT andthe stream 152 itself can have a boiling point lower than the boilingpoint of the principal terephthalyl (or DMT).

In an embodiment or in combination with any embodiment mentioned herein,a light organics solvolysis coproduct stream 152 may be produced in thesolvolysis facility that comprises the principal solvent (e.g.,methanol). For example, the light organics coproduct stream 152 caninclude at least 2, at least 5, at least 10, at least 15, at least 20,at least 25, at least 30, at least 35, at least 40, at least 45, atleast 50, or at least 55 weight percent and/or not more than 90, notmore than 85, not more than 80, not more than 75, not more than 70, notmore than 65, not more than 60, not more than 55, not more than 50, notmore than 45, not more than 40, not more than 35, or not more than 30weight percent of the principal solvent.

In addition, this coproduct stream 152 may also include acetaldehyde inan amount of at least 1, at least 5, at least 10, at least 50, at least100, at least 250, at least 500, at least 750, or at least 1000 ppmand/or not more than 90, not more than 85, not more than 80, not morethan 75, not more than 70, not more than 65, not more than 60, not morethan 55, not more than 50, not more than 45, not more than 40, not morethan 35, not more than 30, not more than 25, not more than 20, not morethan 15, not more than 10, not more than 5, not more than 3, not morethan 2, not more than 1, not more than 0.5, not more than 0.1, or notmore than 0.05 weight percent, based on the total weight of thecoproduct stream, or the acetaldehyde can be present in an amount of 1ppm to 50 weight percent, 50 ppm to 0.5 weight percent, or 100 ppm to0.05 weight percent, based on the total weight of the coproduct stream.

Further, the light organics coproduct stream 152 may also includepara-dioxane (or p-dioxane) in amount of at least 1, at least 5, atleast 10, at least 50, at least 100, at least 250, at least 500, atleast 750, or at least 1000 ppm and/or not more than 60, not more than55, not more than 50, not more than 45, not more than 40, not more than35, not more than 30, not more than 25, not more than 20, not more than15, not more than 10, not more than 5, not more than 3, not more than 2,not more than 1, not more than 0.5, not more than 0.1, or not more than0.05 weight percent, based on the total weight of the coproduct stream,or the p-dioxane can be present in an amount of 1 ppm to 50 weightpercent, 50 ppm to 0.5 weight percent, or 100 ppm to 0.05 weightpercent, based on the total weight of the coproduct stream.

This light organics coproduct stream 152 may further include at leastone additional component selected from the group consisting oftetrahydrofuran (THF), methyl acetate, silicates, 2,5-methyl dioxolane,1,4-cyclohexanedimethanol, 2-ethyl-1-hexanol,2,2,4,4,-tetramethyl-1,3-cyclobutanediol, 2,2,4-trimethyl-3-pentenal,2,2,4-trimethyl-3-pentenol, 2,2,4-trimethylpentane,2,4-dimethyl-3-pentanone (DIPK), isobutyl isobutyrate, methyl formate,n-butanol, acetic acid, dibutyl ether, heptane, dibutyl terephthalate,dimethyl phthalate, dimethyl 1,4-cyclohexanedicarboxylate,2-methoxyethanol, 2-methyl-1,3-dioxolane, 1,1-dimethoxy-2-butene,1,1-dimethoxyethane, 1,3-propanediol, 2,5-dimethyl-1,3,5-hexadiene,2,5-dimethyl-2,4-hexadiene, alpha-methyl styrene, diethylene glycolmethyl ether, diethylene glycol formal, dimethoxydimethyl silane,dimethyl ether, diisopropyl ketone, EG benzoate,hexamethylcyclotrisiloxane, hexamethyldisiloxane,methoxytrimethylsilane, methyl 4-ethylbenzoate, methyl caprylate, methylglycolate, methyl lactate, methyl laurate, methyl methoxyethylterephthalic acid, methyl nonanoate, methyl oleate, methyl palmitate,methyl stearate, methyl-4-acetyl benzoate, octamethylcyclotetrasiloxane,styrene, trimethylsilanol, 1,1-dimethyoxy-2-butene, 4-methyl morpholine,1,3,3-trimethoxypropane, methyl myristate, dimethyl adipate,n-methyl-caprolactam, dimethyl azelate, neopentyl glycol, andcombinations thereof.

As discussed in further detail herein, all or a portion of the lightorganics coproduct stream or streams may be introduced into one or moredownstream chemical recycling facilities alone or in combination withone or more other coproduct streams, streams resulting from one or moreof the other downstream chemical recycling facilities, and/or streams ofwaste plastic, including mixed plastic waste (unprocessed, partiallyprocessed, or processed).

Additionally, a stream predominantly comprising the principal glycol 154may also be withdrawn from the light organics separation zone 230. In anembodiment or in combination with any embodiment mentioned herein, thestream of principal glycol 154 (such as ethylene glycol) can include atleast 55, at least 60, at least 65, at least 70, at least 75, at least80, at least 85, at least 90, at least 95, or at least 99 weight percentof the principal glycol, based on the total weight of the stream 154.The principal glycol stream 154 may also include recycle content, suchthat the principal glycol product stream 154 has a recycle content of atleast 50, at least 55, at least 60, at least 65, at least 70, at least75, at least 80, at least 85, at least 90, or at least 95 weightpercent, based on the total weight of the stream. The principal glycol(or ethylene glycol) can comprise r-glycol (or r-ethylene glycol).

As shown in FIG. 3 , a glycol-containing column bottoms coproduct stream156 may also be withdrawn from the light organics separation zone 230.The terms “glycol column bottoms” or “glycol column sludge” (or, moreparticularly, EG column bottoms or EG column sludge in methanolysis)refers to components that have a boiling point (or azeotrope) higherthan the boiling point of the principal glycol but lower than theprincipal terephthalyl.

In an embodiment or in combination with any embodiment mentioned herein,the glycol column bottoms coproduct stream 156 can comprise at least 50,at least 55, at least 60, at least 65, at least 70, at least 75, atleast 80, at least 85, at least 90, or at least 95 weight percent ofcomponents with a boiling point higher than the boiling point of theprincipal glycol (e.g., ethylene glycol) and lower than the boilingpoint of the principal terephthalyl. The glycol column bottoms coproductstream 156 can comprise not more than 60, not more than 55, not morethan 50, not more than 45, not more than 40, not more than 35, not morethan 30, not more than 25, not more than 20, not more than 15, not morethan 10, not more than 5, not more than 2, not more than 1 weightpercent of components with a boiling point lower than the boiling pointof the principal glycol (e.g., ethylene glycol). The glycol columnbottoms coproduct stream 156 can have a boiling point higher than theboiling point of the principal glycol (e.g., EG) and lower than theboiling point of the principal terephthalyl (e.g., DMT).

In an embodiment or in combination with any embodiment mentioned herein,the glycol bottoms coproduct stream 156 can comprise the principalglycol and at least one other glycol. For example, the glycol columnbottoms coproduct stream 156 can comprise at least 0.5, at least 1, atleast 2, at least 3, at least 5, or at least 8 and/or not more than 30,not more than 25, not more than 20, not more than 15, not more than 12,or not more than 10 weight percent of the primary glycol (or ethyleneglycol), based on the total weight of the coproduct stream 156. Theprincipal glycol (or ethylene glycol) may be present as itself (in afree state) or as a moiety in another compound.

Examples of other possible principal glycols (depending on the PET orother polymer being processed) may include, but are not limited to,diethylene glycol, triethylene glycol, 1,4-cyclohexane-dimethanol,propane-1,3-diol, butane-1,4-diol, pentane-1,5-diol, hexane-1,6-diol,neopentyl glycol, 3-methylpentanediol-(2,4), 2-methylpentanediol-(1,4),2,2,4-trimethylpentane-diol-(1,3), 2-ethylhexanediol-(1,3),2,2-diethylpropane-diol-(1,3), hexanediol-(1,3),1,4-di-(hydroxyethoxy)-benzene, 2,2-bis-(4-hydroxycyclohexyl)-propane,2,4-dihydroxy-1,1,3,3-tetramethyl-cyclobutane, 2,2,4,4tetramethylcyclobutanediol, 2,2-bis-(3-hydroxyethoxyphenyl)-propane,2,2-bis-(4-hydroxypropoxyphenyl)-propane, isosorbide, hydroquinone,BDS-(2,2-(sulfonylbis)4,1-phenyleneoxy))bis(ethanol), and combinationsthereof. The other glycol may not be or comprise ethylene glycol.Moieties of these glycols may also be present in any oligomers ofpolyester in this or other coproduct streams. Additionally, othernon-terephthalyl and/or non-glycol components may also be present inthese streams. Examples of such components include, isophthalates andother acid residues that boil higher than the principal terephthalyl.

In an embodiment or in combination with any embodiment mentioned herein,the glycol other than the principal glycol (or ethylene glycol in thecase of methanolysis) can be present in the glycol column bottomscoproduct stream 156 in an amount of at least 15, at least 20, at least25, at least 30, at least 35, at least 40, at least 45, at least 50, atleast 55, at least 60, at least 65, at least 70, or at least 75 and/ornot more than 99, not more than 95, not more than 90, not more than 85,not more than 80, not more than 75, not more than 70, not more than 65,not more than 60, not more than 55, not more than 50, not more than 45,not more than 40, or not more than 35 weight percent, based on the totalweight of glycols in the glycol column bottoms coproduct stream 156.

In an embodiment or in combination with any embodiment mentioned herein,the weight ratio of the at least one glycol other than the principalglycol to the principal glycol in the glycol column bottoms coproductstream 156 is at least 0.5:1, at least 0.55:1, at least 0.65:1, at least0.70:1, at least 0.75:1, at least 0.80:1, at least 0.85:1, at least0.90:1, at least 0.95:1, at least 0.97:1, at least 0.99:1, at least 1:1,at least 1.05:1, at least 1.1:1, at least 1.15:1, at least 1.2:1, atleast or at least 1.25:1. Additionally, or in the alternative, theweight ratio of the at least one glycol other than the principal glycolto the principal glycol in the glycol column bottoms coproduct stream156 is not more than 5:1, not more than 4.5:1, not more than 4:1, notmore than 3.5:1, not more than 3:1, not more than 2.5:1, not more than2:1, not more than 1.5:1, not more than 1.25:1, or not more than 1:1, orin the range of from 0.5:1 to 5:1, from 0.70:1 to 3:1, or 0.80:1 to2.5:1.

In an embodiment or in combination with any embodiment mentioned herein,the solvolysis facility 30 may produce two or more coproduct streams,which can include two or more heavy organic coproduct streams, two ormore light organic coproduct streams, or combinations of light and heavyorganic coproduct streams. All or a portion of one or more of thesolvolysis coproduct stream or streams (shown as stream 110 in FIG. 1 )may be introduced into at least one of the downstream processingfacilities including, for example, the pyrolysis facility 60, thecracking facility 70, the POX gasification facility 50, the energyrecovery facility 80, and any of the other optional facilities mentionedpreviously.

In an embodiment or in combination with any embodiment mentioned herein,two or more (or portions of two or more) solvolysis coproduct streamsmay be introduced into the same downstream processing facility, while,in other cases, two or more (or portions of two or more) solvolysiscoproduct streams may be introduced into different downstream processingfacilities. In some embodiments, at least 90, at least 95, at least 97,at least 99 weight percent, or all, of a single coproduct stream may beintroduced into one downstream facility, while, in other embodiments,the stream may be divided amongst two or more downstream facilities,such that not more than 60, not more than 55, not more than 50, not morethan 45, not more than 40, not more than 35, or not more than 30 weightpercent of a single coproduct stream may be introduced into one of thedownstream processing facilities.

Referring again to FIG. 1 , in an embodiment or in combination with anyembodiment mentioned herein, at least a portion of at least onesolvolysis coproduct stream 110 may be combined with at least a portionof the PO-enriched plastic stream 114 withdrawn from the pre-processingfacility 20 as shown in FIG. 1 . The amount of a single coproduct stream110 (or all coproduct streams when two or more are combined) in thecombined stream with the PO-enriched plastic may vary and can be, forexample, at least 1, at least 5, at least 10, at least 15, at least 20,at least 25, at least 30, at least 35, at least 40, at least 45, or atleast 50 and/or not more than 90, not more than 85, not more than 80,not more than 75, not more than 70, not more than 65, not more than 60,not more than 55, not more than 50, or not more than 40 weight percent,based on the total weight of the combined stream. As shown in FIG. 1 ,the combined stream may then be introduced into one or more locations ofthe chemical recycling facility, including, for example into a POXgasification facility 50, a pyrolysis facility 60, a cracker facility70, and/or an energy generation facility 80.

Liquification/Dehalogenation

As shown in FIG. 1 , the PO-enriched waste plastic stream 114 (with orwithout being combined with a solvolysis coproduct stream 110) mayoptionally be introduced into a liquification zone or step prior tobeing introduced into one or more of the downstream processingfacilities. As used herein, the term “liquification” zone or step refersto a chemical processing zone or step in which at least a portion of theincoming plastic is liquefied. The step of liquefying plastic caninclude chemical liquification, physical liquification, or combinationsthereof. Exemplary methods of liquefying the polymer introduced into theliquification zone can include (i) heating/melting; (ii) dissolving in asolvent; (iii) depolymerizing; (iv) plasticizing, and combinationsthereof. Additionally, one or more of options (i) through (iv) may alsobe accompanied by the addition of a blending or liquification agent tohelp facilitate the liquification (reduction of viscosity) of thepolymer material. As such, a variety of rheology modification agents(e.g., solvents, depolymerization agents, plasticizers, and blendingagents) can be used the enhance the flow and/or dispersibility of theliquified waste plastic.

When added to the liquification zone 40, at least 50, at least 55, atleast 60, at least 65, at least 70, at least 75, at least 80, at least85, at least 90, at least 95, or at least 99 weight percent of theplastic (usually waste plastic) undergoes a reduction in viscosity. Insome cases, the reduction in viscosity can be facilitated by heating(e.g., addition of steam directly or indirectly contacting the plastic),while, in other cases, it can be facilitated by combining the plasticwith a solvent capable of dissolving it. Examples of suitable solventscan include, but are not limited to, alcohols such as methanol orethanol, glycols such as ethylene glycol, diethylene glycol, triethyleneglycol, neopentyl glycol, cyclohexanedimethanol, glycerin, pyrolysisoil, motor oil, and water. As shown in FIG. 1 , the solvent stream 141can be added directly to the liquification zone 40, or it can becombined with one or more streams fed to the liquification zone (notshown in FIG. 1 ).

In an embodiment or in combination with any embodiment mentioned herein,the solvent can comprise a stream withdrawn from one or more otherfacilities within the chemical recycling facility. For example, thesolvent can comprise a stream withdrawn from at least one of thesolvolysis facility 30, the pyrolysis facility 60, and the crackingfacility 70. The solvent can be or comprise at least one of thesolvolysis coproducts described herein or can be or comprise pyrolysisoil.

In some cases, the plastic can be depolymerized such that, for example,the number average chain length of the plastic is reduced by contactwith a depolymerization agent. In an embodiment or in combination withany embodiment mentioned herein, at least one of the previously-listedsolvents may be used as a depolymerization agent, while, in one or moreother embodiments, the depolymerization agent can include an organicacid (e.g., acetic acid, citric acid, butyric acid, formic acid, lacticacid, oleic acid, oxalic, stearic acid, tartaric acid, and/or uric acid)or inorganic acid such as sulfuric acid (for polyolefin). Thedepolymerization agent may reduce the melting point and/or viscosity ofthe polymer by reducing its number average chain length.

Alternatively, or additionally, a plasticizer can be used in theliquification zone to reduce the viscosity of the plastic. Plasticizersfor polyethylene include, for example, dioctyl phthalate, dioctylterephthalate, glyceryl tribenzoate, polyethylene glycol havingmolecular weight of up to 8,000 Daltons, sunflower oil, paraffin waxhaving molecular weight from 400 to 1,000 Daltons, paraffinic oil,mineral oil, glycerin, EPDM, and EVA. Plasticizers for polypropyleneinclude, for example, dioctyl sebacate, paraffinic oil, isooctyltallate, plasticizing oil (Drakeol 34), naphthenic and aromaticprocessing oils, and glycerin. Plasticizers for polyesters include, forexample, polyalkylene ethers (e.g., polyethylene glycol,polytetramethylene glycol, polypropylene glycol or their mixtures)having molecular weight in the range from 400 to 1500 Daltons, glycerylmonostearate, octyl epoxy soyate, epoxidized soybean oil, epoxy tallate,epoxidized linseed oil, polyhydroxyalkanoate, glycols (e.g., ethyleneglycol, pentamethylene glycol, hexamethylene glycol, etc.), phthalates,terephthalates, trimellitate, and polyethylene glycoldi-(2-ethylhexoate). When used, the plasticizer may be present in anamount of at least 0.1, at least 0.5, at least 1, at least 2, or atleast 5 weight percent and/or not more than 10, not more than 8, notmore than 5, not more than 3, not more than 2, or not more than 1 weightpercent, based on the total weight of the stream, or it can be in arange of from 0.1 to 10 weight percent, 0.5 to 8 weight percent, or 1 to5 weight percent, based on the total weight of the stream.

Further, one or more of the methods of liquifying the waste plasticstream can also include adding at least one blending agent to theplastic before, during, or after the liquification process. Suchblending agents may include for example, emulsifiers and/or surfactants,and may serve to more fully blend the liquified plastic into a singlephase, particularly when differences in densities between the plasticcomponents of a mixed plastic stream result in multiple liquid orsemi-liquid phases. When used, the blending agent may be present in anamount of at least 0.1, at least 0.5, at least 1, at least 2, or atleast 5 weight percent and/or not more than 10, not more than 8, notmore than 5, not more than 3, not more than 2, or not more than 1 weightpercent, based on the total weight of the stream, or it can be in arange of from 0.1 to 10 weight percent, 0.5 to 8 weight percent, or 1 to5 weight percent, based on the total weight of the stream.

When combined with the PO-enriched plastic stream 114 as generally shownin FIG. 1 , the solvolysis coproduct stream (which can include one ormore solvolysis coproducts described herein) may be added beforeintroduction of the PO-enriched waste plastic stream 114 into theliquification zone 40 (as shown by line 113) and/or after removal of theliquified plastic stream from the liquification zone 40 (as shown byline 115). In an embodiment or in combination with any embodimentmentioned herein, at least a portion or all of one or more coproductstreams may also be introduced directly into the liquification zone, asshown in FIG. 1 . In an embodiment or in combination with any embodimentmentioned herein, at least a portion of the PO-enriched waste plasticstream 114 can bypass the liquification zone 40 altogether in line 117and may optionally combined with at least one solvolysis coproductstream 110 as also shown in FIG. 1 .

Additionally, as shown in FIG. 1 , a portion of the pyrolysis oil stream143 withdrawn from the pyrolysis facility 60 can be combined with thePO-enriched plastic stream 114 to form a liquified plastic. Althoughshown as being introduced directly into the liquification zone 40, allor a portion of the pyrolysis oil stream 143 may be combined with thePO-enriched plastic stream 114 prior to introduction into theliquification zone 40, or after the PO-enriched plastic stream 114 exitsthe liquification zone 40. When used, the pyrolysis oil can be added atone or more locations described herein, alone or in combination with oneor more other solvent streams.

In an embodiment or in combination with any embodiment mentioned herein,the feed stream to one or more of the downstream chemical recyclingfacilities from the liquification zone 40 can comprise at least 1, atleast 5, at least 10, at least 15, at least 20, at least 25, at least30, at least 35, at least 40, at least 45, at least 50, at least 55, atleast 60, at least 65, at least 70, at least 75, at least 80, at least85, at least 90, or at least 95 weight percent of one or more solvolysiscoproduct streams, based on the total weight of the feed streamintroduced into the downstream processing facility or facilities. Forexample, the feed streams 116, 118, 120, and 122 to each of the POXfacility 50, the pyrolysis facility 60, the cracking facility 70, theenergy recovery facility 80, and/or any other facility 90 of thechemical recycling facility 10 may include PO-enriched waste plastic andan amount of one or more solvolysis coproducts described herein.

Additionally, or in the alternative, the feed stream to the pyrolysisfacility 60, the POX facility 50, the cracking facility 70, the energyrecovery facility 80, and/or any other facility 90 can comprise not morethan 95, not more than 90, not more than 85, not more than 80, not morethan 75, not more than 70, not more than 65, not more than 60, not morethan 55, not more than 50, not more than 45, not more than 40, not morethan 35, not more than 30, not more than 25, not more than 20, not morethan 15, not more than 10, not more than 5, not more than 2, or not morethan 1 weight percent of one or more solvolysis coproduct streams, basedon the total weight of the feed stream introduced into the downstreamprocessing facility or facilities.

Alternatively, or in addition, the liquified (or reduced viscosity)plastic stream withdrawn from the liquification zone 40 can include atleast 1, at least 5, at least 10, at least 15, at least 20, at least 25,at least 30, at least 35, at least 40, at least 45, at least 50, atleast 55, at least 60, at least 65, at least 70, at least 75, at least80, at least 85, at least 90, or at least 95 weight percent and/or notmore than 95, not more than 90, not more than 85, not more than 80, notmore than 75, not more than 70, not more than 65, not more than 60, notmore than 55, not more than 50, not more than 45, not more than 40, notmore than 35, not more than 30, not more than 25, not more than 20, notmore than 15, not more than 10, not more than 5, not more than 2, or notmore than 1 weight percent of PO, based on the total weight of thestream, or the amount of PO can be in the range of from 1 to 95 weightpercent, 5 to 90 weight percent, or to 85 weight percent, based on thetotal weight of the stream.

In an embodiment or in combination with any embodiment mentioned herein,the liquified plastic stream exiting the liquification zone 40 can havea viscosity of less than 3,000, less than 2,500, less than 2,000, lessthan 1,500, less than 1,000, less than 800, less than 750, less than700, less than 650, less than 600, less than 550, less than 500, lessthan 450, less than 400, less than 350, less than 300, less than 250,less than 150, less than 100, less than 75, less than 50, less than 25,less than 10, less than 5, or less than 1 poise, measured using aBrookfield R/S rheometer with V80-40 vane spindle operating at a shearrate of 10 rad/s and a temperature of 350° C. In an embodiment or incombination with any embodiment mentioned herein, the viscosity(measured at 350° C. and 10 rad/s and expressed in poise) of theliquified plastic stream exiting the liquification zone is not more than95, not more than 90, not more than 75, not more than 50, not more than25, not more than 10, not more than 5, or not more than 1 percent of theviscosity of the PO-enriched stream introduced into the liquificationzone.

FIG. 6 shows the basic components in a liquification system that may beused as the liquification zone 40 in the chemical recycling facilityillustrated in FIG. 1 . It should be understood that FIG. 6 depicts oneexemplary embodiment of a liquification system. Certain featuresdepicted in FIG. 6 may be omitted and/or additional features describedelsewhere herein may be added to the system depicted in FIG. 6 .

As shown in FIG. 6 , a waste plastic feed, such as the PO-enriched wasteplastic stream 114, may be derived from a waste plastic source, such asthe preprocessing facility 20 discussed herein. The waste plastic feed,such as the PO-enriched waste plastic stream 114, may be introduced intothe liquification zone 40, which FIG. 6 depicts as containing at leastone melt tank 310, at least one circulation loop pump 312, at least oneexternal heat exchanger 340, at least one stripping column 330, and atleast one disengagement vessel 320. These various exemplary componentsand their functionality in the liquification zone 40 are discussed ingreater detail below.

In an embodiment or in combination with any embodiment mentioned herein,and as shown in FIG. 6 , the liquification zone 40 includes a melt tank310 and a heater. The melt tank 310 receives the waste plastic feed,such as PO-enriched waste plastic stream 114, and the heater heats thewaste plastic. In an embodiment or in combination with any embodimentmentioned herein, the melt tank 310 can include one or more continuouslystirred tanks. When one or more rheology modification agents (e.g.,solvents, depolymerization agents, plasticizers, and blending agents)are used in the liquification zone, such rheology modification agentscan be added to and/or mixed with the PO-enriched plastic in or prior tothe melt tank 310.

In an embodiment or in combination with any embodiment mentioned herein(not shown in FIG. 6 ), the heater of the liquification zone 40 can takethe form of internal heat exchange coils located in the melt tank 310, ajacketing on the outside of the melt tank 310, a heat tracing on theoutside of the melt tank 310, and/or electrical heating elements on theoutside of the melt tank 310. Alternatively, as shown in FIG. 6 , theheater of the liquification zone can include an external heat exchanger340 that receives a stream of liquified plastic 171 from the melt tank310, heats it, and returns at least a portion of the heated liquifiedplastic stream 173 to the melt tank 310.

As shown in FIG. 6 , when an external heat exchanger 340 is used toprovide heat for the liquification zone 40, a circulation loop can beemployed to continuously add heat to the PO-enriched material. In anembodiment or in combination with any embodiment mentioned herein, thecirculation loop includes the melt tank 310, the external heat exchanger340, conduits, shown as line 171, connecting the melt tank and theexternal heat exchanger, and a pump 151 for circulating liquified wasteplastic in the circulation loop. When a circulation loop is employed,the liquified PO-enriched material produced can be continuouslywithdrawn from the liquification zone 40 as a fraction of thecirculating PO-enriched stream via conduit 161 shown in FIG. 6 .

In an embodiment or in combination with any embodiment mentioned herein,the liquification zone 40 may optionally contain equipment for removinghalogens from the PO-enriched material. When the PO-enriched material isheated in the liquification zone 40, halogen enriched gases can evolve.By disengaging the evolved halogen-enriched gasses from the liquifiedPO-enriched material, the concentration of halogens in the PO-enrichedmaterial can be reduced.

In an embodiment or in combination with any embodiment mentioned herein,dehalogenation can be promoted by sparging a stripping gas (e.g., steam)into the liquified PO-enriched material either in the melt tank 310 orat another location in the circulation loop. As shown in FIG. 6 , astripper 330 and a disengagement vessel 320 can be provided in thecirculation loop downstream of the external heat exchanger 340 andupstream of the melt tank 310. As shown in FIG. 6 , the stripper 330 canreceive the heated liquified plastic stream 173 from the external heatexchanger 340 and provide for the sparging of a stripping gas 153 intothe liquified plastic. Sparging of a stripping gas 153 into theliquified plastic can create a two-phase medium in the stripper 330.

This two-phase medium introduced into the disengagement vessel 320 viastream 175 can then be flowed (e.g., by gravity) through thedisengagement vessel 320, where a halogen-enriched gaseous phase isdisengaged from a halogen-depleted liquid phase and removed from thedisengagement vessel 320 via stream 162. Alternatively, a portion of theheated liquefied plastic 173 from the external heat exchanger 340 maybypass the stripper 330 and be introduced directly into thedisengagement vessel 320. In an embodiment or in combination with anyembodiment mentioned herein, a first portion of the halogen-depletedliquid phase discharged from an outlet of the disengagement vessel canbe returned to the melt tank 310 in line 159, while a second portion ofthe halogen-depleted liquid phase can be discharged from theliquification zone as the dehalogenated, liquified, PO-enriched productstream 161. The disengaged halogen-enriched gaseous stream from thedisengagement vessel 162 and from the melt tank 310 in line 164 can beremoved from the liquification zone 40 for further processing and/ordisposal.

In an embodiment or in combination with any embodiment mentioned herein,the dehalogenated liquified waste plastic stream 161 exiting theliquification zone 40 can have a halogen content of less than 500, lessthan 400, less than 300, less than 200, less than 100, less than 50,less than 10, less than 5, less than 2, less than 1, less than 0.5, orless than 0.1 ppmw. The halogen content of the liquified plastic stream161 exiting the liquification zone is not more than 95, not more than90, not more than 75, not more than 50, not more than 25, not more than10, or not more than 5 percent by weight of the halogen content of thePO-enriched stream introduced into the liquification zone.

As shown in FIG. 6 , at least a portion of the dehalogenated liquifiedwaste plastic stream 161 may be introduced into a downstream POXgasifier at a POX gasification facility 50 to produce a syngascomposition and/or a downstream pyrolysis reactor at a pyrolysisfacility 60 to produce pyrolysis vapors (i.e., pyrolysis gas andpyrolysis oil) and pyrolysis residue. Alternatively, or in addition, atleast a portion of the dehalogenated liquified waste plastic stream 161may be introduced into an energy recovery facility 80 and/or one or moreother facilities 90, such as a separation or solidification facility.

In an embodiment or in combination with any embodiment mentioned herein,the chemical recycling facility 10 may not include a liquification zone40. Alternatively, the chemical recycling facility may include aliquification zone 40 but may not include any type of dehalogenationzone or equipment.

Referring again to FIG. 1 , at least a portion of a PO-enriched plasticstream 114 from the preprocessing facility 20 and/or from liquificationzone 40 (alone or in combination with one or more solvolysis coproductstreams 110) may be introduced into one or more of the downstreamprocessing facilities including, for example, the pyrolysis facility 60,the cracking facility 70, the POX gasification facility 50, the energyrecovery facility 80, and any of the other optional facilities 90 asdiscussed in detail below.

Pyrolysis

In an embodiment or in combination with any embodiment mentioned herein,the chemical recycling facility 10 generally depicted in FIG. 1 maycomprise a pyrolysis facility. As used herein the term “pyrolysis”refers to the thermal decomposition of one or more organic materials atelevated temperatures in an inert (i.e., substantially oxygen free)atmosphere. A “pyrolysis facility” is a facility that includes allequipment, lines, and controls necessary to carry out pyrolysis of wasteplastic and feedstocks derived therefrom.

FIG. 7 depicts an exemplary pyrolysis facility 60 for converting a wasteplastic stream 116, such as the liquefied waste plastic from aliquification zone, into a pyrolysis gas, a pyrolysis oil, and apyrolysis residue. It should be understood that FIG. 7 depicts oneexemplary embodiment of the present technology. Thus, certain featuresdepicted in FIG. 7 may be omitted and/or additional features describedelsewhere herein may be added to the system depicted in FIG. 7 .

In an embodiment or in combination with any embodiment mentioned herein,a feed stream 116 to the pyrolysis facility 60 may comprise at least oneof (i) at least one solvolysis coproduct stream as described previously,and (ii) a PO-enriched stream of waste plastic. One or more of thesestreams may be introduced into the pyrolysis facility 60 continuously orone or more of these streams may be introduced intermittently. Whenmultiple types of feed streams are present, each may be introducedseparately, or all or a portion of the streams may be combined so thatthe combined stream may be introduced into the pyrolysis facility 60.The combining, when performed, may take place in a continuous or batchmanner. The feed introduced into the pyrolysis facility 60 can be in theform of liquified plastic (e.g., liquified, melted, plasticized,depolymerized, or combinations thereof), plastic pellets orparticulates, or a slurry thereof.

In general, and as depicted in FIG. 7 , the pyrolysis facility 60includes a pyrolysis reactor 510 and a separator 520 for separating theproduct stream from the reactor. Although not depicted in FIG. 7 , theseparator 520 of the pyrolysis facility 60 can include various types ofequipment including, but not limited to a filter system, a multistageseparator, a condenser, and/or a quench tower.

While in the pyrolysis reactor 510, at least a portion of the feed maybe subjected to a pyrolysis reaction that produces a pyrolysis effluentcomprising a pyrolysis oil, a pyrolysis gas, and a pyrolysis residue. Asused herein, the term “pyrolysis gas” refers to a composition obtainedfrom pyrolysis that is gaseous at 25° C. at 1 atm. As used herein, theterms “pyrolysis oil” or “pyoil” refers to a composition obtained frompyrolysis that is liquid at 25° C. and 1 atm. As used herein, the term“pyrolysis residue” refers to a composition obtained from pyrolysis thatis not pyrolysis gas or pyrolysis oil and that comprises predominantlypyrolysis char and pyrolysis heavy waxes. As used herein, the term“pyrolysis char” refers to a carbon-containing composition obtained frompyrolysis that is solid at 200° C. and 1 atm. As used herein, the term“pyrolysis heavy waxes,” refers to C20+ hydrocarbons obtained frompyrolysis that are not pyrolysis char, pyrolysis gas, or pyrolysis oil.The pyrolysis gas and pyrolysis oil may exit the pyrolysis reactor 500as a pyrolysis vapor stream 170.

Pyrolysis is a process that involves the chemical and thermaldecomposition of the introduced feed. Although all pyrolysis processesmay be generally characterized by a reaction environment that issubstantially free of oxygen, pyrolysis processes may be furtherdefined, for example, by the pyrolysis reaction temperature within thereactor, the residence time in the pyrolysis reactor, the reactor type,the pressure within the pyrolysis reactor, and the presence or absenceof pyrolysis catalysts.

In an embodiment or in combination with any embodiment mentioned herein,the pyrolysis reactor 510 can be, for example, a film reactor, a screwextruder, a tubular reactor, a tank, a stirred tank reactor, a riserreactor, a fixed bed reactor, a fluidized bed reactor, a rotary kiln, avacuum reactor, a microwave reactor, or an autoclave. The pyrolysisreactor 510 comprises a film reactor, such as a falling film reactor oran up-flow film reactor.

In an embodiment or in combination with any embodiment mentioned herein,the pyrolysis reaction can involve heating and converting the feedstockin an atmosphere that is substantially free of oxygen or in anatmosphere that contains less oxygen relative to ambient air. Forexample, the atmosphere within the pyrolysis reactor 510 may comprisenot more than 5, not more than 4, not more than 3, not more than 2, notmore than 1, or not more than 0.5 percent of oxygen gas based on theinterior volume of the reactor 510.

In an embodiment or in combination with any embodiment mentioned herein,a lift gas and/or a feed gas may be used to introduce the feedstock intothe pyrolysis reactor 510 and/or facilitate various reactions within thepyrolysis reactor 510. For instance, the lift gas and/or the feed gasmay comprise, consist essentially of, or consist of nitrogen, carbondioxide, and/or steam. The lift gas and/or feed gas may be added withthe waste plastic stream 116 prior to introduction into the pyrolysisreactor 510 and/or may be added directly to the pyrolysis reactor 510.The lift gas and/or feed gas can include steam and/or a reducing gassuch as hydrogen, carbon monoxide, and combinations thereof.

Furthermore, the temperature in the pyrolysis reactor 510 can beadjusted so as to facilitate the production of certain end products. Inan embodiment or in combination with any embodiment mentioned herein,the pyrolysis temperature in the pyrolysis reactor 510 can be at least325° C., at least 350° C., at least 375° C., at least 400° C., at least425° C., at least 450° C., at least 475° C., at least 500° C., at least525° C., at least 550° C., at least 575° C., at least 600° C., at least625° C., at least 650° C., at least 675° C., at least 700° C., at least725° C., at least 750° C., at least 775° C., or at least 800° C.

Additionally or alternatively, the pyrolysis temperature in thepyrolysis reactor can be not more than 1,100° C., not more than 1,050°C., not more than 1,000° C., not more than 950° C., not more than 900°C., not more than 850° C., not more than 800° C., not more than 750° C.,not more than 700° C., not more than 650° C., not more than 600° C., notmore than 550° C., not more than 525° C., not more than 500° C., notmore than 475° C., not more than 450° C., not more than 425° C., or notmore than 400° C. More particularly, the pyrolysis temperature in thepyrolysis reactor can range from 325 to 1,100° C., 350 to 900° C., 350to 700° C., 350 to 550° C., 350 to 475° C., 425 to 1,100° C., 425 to800° C., 500 to 1,100° C., 500 to 800° C., 600 to 1,100° C., 600 to 800°C., 650 to 1,000° C., or 650 to 800° C.

In an embodiment or in combination with any embodiment mentioned herein,the residence times of the feedstocks within the pyrolysis reactor canbe at least 0.1, at least 0.2, at least 0.3, at least 0.5, at least 1,at least 1.2, at least 1.3, at least 2, at least 3, or at least 4seconds. Alternatively, the residence times of the feedstocks within thepyrolysis reactor can be at least 1, at least 2, at least 3, at least 4,at least 5, at least 6, at least 7, at least 8, at least 9, at least 10,at least 20, at least 30, at least 45, at least 60, at least 75, or atleast 90 minutes. Additionally, or alternatively, the residence times ofthe feedstocks within the pyrolysis reactor can be less than 6, lessthan 5, less than 4, less than 3, less than 2, less than 1, or less than0.5 hours. Furthermore, the residence times of the feedstocks within thepyrolysis reactor can be less than 100, less than 90, less than 80, lessthan 70, less than 60, less than 50, less than 40, less than 30, lessthan 20, less than 10, less than 9, less than 8, less than 7, less than6, less than 5, less than 4, less than 3, less than 2, or less than 1seconds. More particularly, the residence times of the feedstocks withinthe pyrolysis reactor can range from 0.1 to 10 seconds, 0.5 to 10seconds, 30 minutes to 4 hours, or 30 minutes to 3 hours, or 1 hour to 3hours, or 1 hour to 2 hours.

In an embodiment or in combination with any embodiment mentioned herein,the pressure within the pyrolysis reactor can be maintained at apressure of at least 0.1, at least 0.2, or at least 0.3 bar and/or notmore than 60, not more than 50, not more than 40, not more than 30, notmore than 20, not more than 10, not more than 8, not more than 5, notmore than 2, not more than 1.5, or not more than 1.1 bar. The pressurewithin the pyrolysis reactor can be maintained at atmospheric pressureor within the range of 0.1 to 100 bar, or 0.1 to 60 bar, or 0.1 to 30bar, or 0.1 to 10 bar, or 1.5 bar, 0.2 to 1.5 bar, or 0.3 to 1.1 bar.The pressure within the pyrolysis reactor can be at least 10, at least20, at least 30, at least 40, at least 50, at least 60, or at least 70bar and/or not more than 100, not more than 95, not more than 90, notmore than 85, not more than 80, not more than 75, not more than 70, notmore than 65, or not more than 60 bar. As used herein, the term “bar”refers to gauge pressure, unless otherwise noted.

In an embodiment or in combination with any embodiment mentioned herein,a pyrolysis catalyst may be introduced into the feed stream 116 prior tointroduction into the pyrolysis reactor 510 and/or introduced directlyinto the pyrolysis reactor 510. The catalyst can be homogenous orheterogeneous and may include, for example, certain types of zeolitesand other mesostructured catalysts. In some embodiments, the pyrolysisreaction may not be catalyzed (e.g., carried out in the absence of apyrolysis catalyst), but may include a non-catalytic, heat-retaininginert additive, such as sand, in the reactor 510 in order to facilitatethe heat transfer. Such catalyst-free pyrolysis processes may bereferred to as “thermal pyrolysis.”

In an embodiment or in combination with any embodiment mentioned herein,the pyrolysis reaction in the pyrolysis reactor 510 may occur in thesubstantial absence of a pyrolysis catalyst, at a temperature in therange of 350 to 600° C., at a pressure ranging from 0.1 to 100 bar, andat a residence time of 0.2 seconds to 4 hours, or 0.5 hours to 3 hours.

In an embodiment or in combination with any embodiment mentioned herein,the pyrolysis effluent or pyrolysis vapors may comprise at least 1, atleast 5, at least 10, at least 15, at least 20, at least 25, at least30, at least 35, at least 40, at least 45, at least 50, at least 55, atleast 60, at least 65, at least 70, or at least 75 weight percent of thepyrolysis oil, which may be in the form of vapors in the pyrolysiseffluent upon exiting the heated reactor; however, these vapors may besubsequently condensed into the resulting pyrolysis oil. Additionally,or alternatively, the pyrolysis effluent or pyrolysis vapors maycomprise not more than 99, not more than 95, not more than 90, not morethan 85, not more than 80, not more than 75, not more than 70, not morethan 65, not more than 60, not more than 55, not more than 50, not morethan 45, not more than 40, not more than 35, not more than 30, or notmore than 25 weight percent of the pyrolysis oil, which may be in theform of vapors in the pyrolysis effluent upon exiting the heatedreactor. The pyrolysis effluent or pyrolysis vapors may comprise in therange of 20 to 99 weight percent, 25 to 80 weight percent, 30 to 85weight percent, 30 to 80 weight percent, 30 to 75 weight percent, 30 to70 weight percent, or 30 to 65 weight percent of the pyrolysis oil,based on the total weight of the pyrolysis effluent or pyrolysis vapors.

In an embodiment or in combination with any embodiment mentioned herein,the pyrolysis effluent or pyrolysis vapors may comprise at least 1, atleast 5, at least 10, at least 15, at least 20, at least 25, at least30, at least 35, at least 40, at least 45, at least 50, at least 55, atleast 60, at least 65, at least 70, at least 75, or at least 80 weightpercent of the pyrolysis gas. Additionally, or alternatively, thepyrolysis effluent or pyrolysis vapors may comprise not more than 99,not more than 95, not more than 90, not more than 85, not more than 80,not more than 75, not more than 70, not more than 65, not more than 60,not more than 55, not more than 50, or not more than 45 weight percentof the pyrolysis gas. The pyrolysis effluent may comprise 1 to 90 weightpercent, to 85 weight percent, 15 to 85 weight percent, 20 to 80 weightpercent, 25 to 80 weight percent, 30 to 75 weight percent, or 35 to 75weight percent of the pyrolysis gas, based on the total weight of thestream.

In an embodiment or in combination with any embodiment mentioned herein,the pyrolysis effluent or pyrolysis vapors may comprise at least 0.5, atleast 1, at least 2, at least 3, at least 4, at least 5, at least 6, atleast 7, at least 8, at least 9, or at least 10 weight percent of thepyrolysis residue. Additionally, or alternatively, the pyrolysiseffluent may comprise not more than 60, not more than 50, not more than40, not more than 30, not more than 25, not more than 20, not more than15, not more than 10, not more than 9, not more than 8, not more than 7,not more than 6, or not more than 5 weight percent of the pyrolysisresidue. The pyrolysis effluent may comprise in the range of 0.1 to 25weight percent, 1 to 15 weight percent, 1 to 8 weight percent, or 1 to 5weight percent of the pyrolysis residue, based on the total weight ofthe stream.

In an embodiment or in combination with any embodiment mentioned herein,the pyrolysis effluent or pyrolysis vapors may comprise not more than15, not more than 14, not more than 13, not more than 12, not more than11, not more than 10, not more than 9, not more than 8, not more than 7,not more than 6, not more than 5, not more than 4, not more than 3, notmore than 2, not more than 1, or not more than 0.5 weight percent offree water. As used herein, “free water” refers to water previouslyadded (as liquid or steam) to the pyrolysis unit and water generated inthe pyrolysis unit.

The pyrolysis system described herein may produce a pyrolysis effluentthat can be separated into a pyrolysis oil stream 174, a pyrolysis gasstream 172, and a pyrolysis residue stream 176, each of which may bedirectly used in various downstream applications based on theirformulations. The various characteristics and properties of thepyrolysis oil, pyrolysis gas, and pyrolysis residue are described below.It should be noted that, while all of the following characteristics andproperties may be listed separately, it is envisioned that each of thefollowing characteristics and/or properties of the pyrolysis gas,pyrolysis oil, and/or pyrolysis residue are not mutually exclusive andmay be combined and present in any combination.

In an embodiment or in combination with any embodiment mentioned herein,the pyrolysis oil may predominantly comprise hydrocarbons having from 4to 30 carbon atoms per molecule (e.g., C4 to C30 hydrocarbons). As usedherein, the term “Cx” or “Cx hydrocarbon,” refers to a hydrocarboncompound including “x” total carbons per molecule, and encompasses allolefins, paraffins, aromatics, heterocyclic, and isomers having thatnumber of carbon atoms. For example, each of normal, iso, andtert-butane and butene and butadiene molecules would fall under thegeneral description “C4.” The pyrolysis oil may have a C4-C30hydrocarbon content of at least 55, at least 60, at least 65, at least70, at least 75, at least 80, at least 85, at least 90, or at least 95weight percent based on the total weight of the pyrolysis oil stream174.

In an embodiment or in combination with any embodiment mentioned herein,the pyrolysis oil can predominantly comprise C5 to C25 hydrocarbons, C5to C22 hydrocarbons, or C5 to C20 hydrocarbons. For example, thepyrolysis oil may comprise at least 55, at least 60, at least 65, atleast 70, at least 75, at least 80, at least 85, at least 90, or atleast 95 weight percent of C5 to C25 hydrocarbons, C5 to C22hydrocarbons, or C5 to C20 hydrocarbons, based on the total weight ofthe pyrolysis oil. The pyrolysis oil may have a C5-C12 hydrocarboncontent of at least 5, at least 10, at least 15, at least 20, at least25, at least 30, at least 35, at least 40, at least 45, at least 50, orat least 55 weight percent based on the total weight of the pyrolysisoil. Additionally, or alternatively, the pyrolysis oil may have a C5-C12hydrocarbon content of not more than 95, not more than 90, not more than85, not more than 80, not more than 75, not more than 70, not more than65, not more than 60, not more than 55, or not more than 50 weightpercent. The pyrolysis oil may have a C5-C12 hydrocarbon content in therange of 10 to 95 weight percent, 20 to 80 weight percent, or 35 to 80weight percent, based on the total weight of the stream.

In an embodiment or in combination with any embodiment mentioned herein,the pyrolysis oil may also include various amounts of olefins andaromatics depending on reactor conditions and whether or not a catalystis employed. The pyrolysis oil comprises at least 1, at least 5, atleast 10, at least 15, at least 20, at least 25, at least 30, at least35, or at least 40 weight percent of olefins and/or aromatics based onthe total weight of the pyrolysis oil. Additionally, or alternatively,the pyrolysis oil may include not more than 90, not more than 80, notmore than 70, not more than 60, not more than 50, not more than 45, notmore than 40, not more than 35, not more than 30, not more than 25, notmore than 20, not more than 15, not more than 10, not more than 5, ornot more than 1 weight percent of olefins and/or aromatics. As usedherein, the term “aromatics” refers to the total amount (in weight) ofany compounds containing an aromatic moiety, such as benzene, toluene,xylene, and styrene.

In an embodiment or in combination with any embodiment mentioned herein,the pyrolysis oil may have a paraffin (e.g., linear or branch alkanes)content of at least 5, at least 10, at least 15, at least 20, at least25, at least 30, at least 35, at least 40, at least 45, at least 50, atleast 55, at least 60, or at least 65 weight percent based on the totalweight of the pyrolysis oil. Additionally, or alternatively, thepyrolysis oil may have a paraffin content of not more than 99, not morethan 97, not more than 95, not more than 93, not more than 90, not morethan 85, not more than 80, not more than 75, not more than 70, not morethan 65, not more than 60, not more than 55, not more than 50, not morethan 45, not more than 40, not more than 35, or not more than 30 weightpercent. The pyrolysis oil may have a paraffin content in the range ofto 90 weight percent, 35 to 90 weight percent, or 50 to 80 weightpercent.

In an embodiment or in combination with any embodiment mentioned herein,the pyrolysis oil may have a mid-boiling point of at least 75° C., atleast 80° C., at least 85° C., at least 90° C., at least 95° C., atleast 100° C., at least 105° C., at least 110° C., or at least 115° C.and/or not more than 250° C., not more than 245° C., not more than 240°C., not more than 235° C., not more than 230° C., not more than 225° C.,not more than 220° C., not more than 215° C., not more than 210° C., notmore than 205° C., not more than 200° C., not more than 195° C., notmore than 190° C., not more than 185° C., not more than 180° C., notmore than 175° C., not more than 170° C., not more than 165° C., notmore than 160° C., not more than 155° C., not more than 150° C., notmore than 145° C., not more than 140° C., not more than 135° C., notmore than 130° C., not more than 125° C., or not more than 120° C., asmeasured according to ASTM D-5399. The pyrolysis oil may have amid-boiling point in the range of 75 to 250° C., 90 to 225° C., or 115to 190° C. As used herein, “mid-boiling point” refers to the medianboiling point temperature of the pyrolysis oil, where 50 percent byvolume of the pyrolysis oil boils above the mid-boiling point and 50percent by volume boils below the mid-boiling point.

In an embodiment or in combination with any embodiment mentioned herein,the boiling point range of the pyrolysis oil may be such that at least90 percent of the pyrolysis oil boils off at a temperature of 250° C.,of 280° C., of 290° C., of 300° C., or of 310° C., as measured accordingto ASTM D-5399.

Turning to the pyrolysis gas, the pyrolysis gas can have a methanecontent of at least 1, at least 2, at least 3, at least 4, at least 5,at least 6, at least 7, at least 8, at least 9, at least 10, at least11, at least 12, at least 13, at least 14, or at least 15 and/or notmore than 50, not more than 45, not more than 40, not more than 35, notmore than 30, not more than 25, or not more than 20 weight percent basedon the total weight of the pyrolysis gas. In an embodiment or incombination with any embodiment mentioned herein, the pyrolysis gas canhave a methane content in the range of 1 to 50 weight percent, 5 to 50weight percent, or 15 to 45 weight percent.

In an embodiment or in combination with any embodiment mentioned herein,the pyrolysis gas can have a C3 and/or C4 hydrocarbon content (includingall hydrocarbons having 3 or 4 carbon atoms per molecule) of at least 5,at least 10, at least 15, at least 20, at least 25, at least 30, atleast 35, at least 40, at least 45, at least 50, at least 55, or atleast 60 and/or not more than 99, not more than 95, not more than 90,not more than 85, not more than 80, not more than 75, not more than 70,or not more than 65 weight percent based on the total weight of thepyrolysis gas. The pyrolysis gas can have a C3 hydrocarbon content, a C4hydrocarbon content, or combined C3 and C4 hydrocarbon content in therange of 10 to 90 weight percent, 25 to 90 weight percent, or 25 to 80weight percent.

In an embodiment or in combination with any embodiment mentioned herein,the pyrolysis gas can make up at least 10, at least 20, at least 30, atleast 40, or at least 50 weight percent of the total effluent from thepyrolysis reactor and the pyrolysis gas can have a combined ethylene andpropylene content of at least 25, at least 40, at least 50, at least 60,at least 70, or at least 75 percent by total weight of the pyrolysisgas.

Turning to the pyrolysis residue, in an embodiment or in combinationwith any embodiment mentioned herein, the pyrolysis residue comprises atleast 20, at least 25, at least 30, at least 35, at least 40, at least45, at least 50, at least 55, at least 60, at least 65, at least 70, atleast 75, at least 80, or at least 85 weight percent of C20+hydrocarbons based on the total weight of the pyrolysis residue. As usedherein, “C20+ hydrocarbon” refers to hydrocarbon compounds containing atleast 20 total carbons per molecule, and encompasses all olefins,paraffins, and isomers having that number of carbon atoms.

In an embodiment or in combination with any embodiment mentioned herein,the pyrolysis residue comprises at least 1, at least 2, at least 5, atleast 10, at least 15, at least 20, at least 25, at least 30, at least35, at least 40, at least 45, at least 50, at least 55, at least 60, atleast 65, at least 70, at least 75, at least 80, at least 85, at least90, at least 95, or at least 99 weight percent of carbon-containingsolids based on the total weight of the pyrolysis residue. Additionally,or alternatively, the pyrolysis residue comprises not more than 99, notmore than 90, not more than 80, not more than 70, not more than 60, notmore than 50, not more than 40, not more than 30, not more than 20, notmore than 10, not more than 9, not more than 8, not more than 7, notmore than 6, not more than 5, or not more than 4 weight percent ofcarbon-containing solids. As used herein, “carbon-containing solids”refer to carbon-containing compositions that are derived from pyrolysisand are solid at 25° C. and 1 atm. The carbon-containing solids compriseat least 20, at least 30, at least 40, at least 50, at least 60, atleast 70, at least 80, or at least 90 weight percent of carbon based onthe total weight of the carbon-containing solids.

In an embodiment or in combination with any embodiment mentioned herein,at least a portion of the pyrolysis gas, pyrolysis oil, and pyrolysisresidue may be routed to one or more of the other chemical processingfacilities, including, for example, the energy recovery facility 80, thepartial oxidation facility 50, one or more of the other facilities 90discussed previously, and the cracking facility 70. In some embodiments,at least a portion of the pyrolysis gas stream 172 and/or at least aportion of the pyrolysis oil (pyoil) stream 174 can be introduced intothe energy recovery facility 80, the cracking facility 70, the POXgasification facility 50, and combinations thereof, while the pyrolysisresidue stream 176 may be introduced into the POX gasification facility50 and/or the energy recovery facility 80. In some embodiments, at leasta portion of the pyrolysis gas stream 172, pyrolysis oil stream 174,and/or pyrolysis residue stream 176 may be routed to one or moreseparation facilities (not shown in FIG. 1 ) to thereby form morepurified streams of the pyrolysis gas, pyrolysis oil, and/or pyrolysisresidue, which may then be routed to the energy recovery facility 80,the cracking facility 70, and/or the POX gasification facility 50.Additionally, or alternatively, all or a portion of the pyrolysis oilstream 176 can be combined with the PO-enriched waste plastic stream 114to provide a liquified plastic stream fed to one or more of thedownstream facilities as discussed herein.

Cracking

In an embodiment or in combination with any embodiment mentioned herein,at least a portion of one or more streams from the pyrolysis facility60, or from one or more of the other facilities shown in FIG. 1 , may beintroduced into a cracking facility 70. As used herein, the term“cracking” refers to breaking down complex organic molecules intosimpler molecules by the breaking of carbon-carbon bonds. A “crackingfacility” is a facility that includes all equipment, lines, and controlsnecessary to carry out cracking of a feedstock derived from wasteplastic. A cracking facility can include one or more cracker furnaces,as well as a downstream separation zone including equipment used toprocess the effluent of the cracker furnace(s). As used herein, theterms “cracker” and “cracking” are used interchangeably.

Turning now to FIG. 8 a , a cracking facility 70 configured according toone or more embodiments of the present technology is shown. In general,the cracker facility 70 includes a cracker furnace 720 and a separationzone 740 downstream of the cracker furnace 720 for separating thefurnace effluent into various end products, such as a recycle contentolefin (r-olefin) stream 130. As shown in FIG. 8 a , at least a portionof the pyrolysis gas stream 172 and/or pyrolysis oil stream 174 from apyrolysis facility 60 can be sent to the cracking facility 70. Thepyrolysis oil stream 174 may be introduced into the inlet of the crackerfurnace 720, while the pyrolysis gas stream 172 can be introduced into alocation upstream or downstream of the furnace 720. As also shown inFIG. 8 a , a stream of paraffin 132 (e.g., ethane and/or propane) may bewithdrawn from the separation zone and may include recycle-contentparaffin (r-paraffin). All or a portion of the paraffin may be recycledvia stream 134 to the inlet of cracker furnace 720 as also shown in FIG.8 a . When used, the pyrolysis oil stream, pyrolysis gas stream 172, andrecycled paraffin stream 174 may optionally be combined with a stream ofcracker feed 136 to form the feed stream 119 to the cracking facility720.

In an embodiment or in combination with any embodiment mentioned herein,a feed stream 119 to the cracking facility 70 may comprise at least oneof (i) one or more solvolysis coproduct streams 110 as describedpreviously, (ii) a PO-enriched stream of waste plastic 114, and (iii) apyrolysis stream (e.g., pyrolysis gas 172 and/or pyrolysis oil 174). Oneor more of these streams may be introduced into the cracking facility 70continuously or one or more of these streams may be introducedintermittently. When multiple types of feed streams are present, eachmay be introduced separately or all, or a portion of, the streams may becombined so that the combined stream may be introduced into the crackingfacility 70. The combining, when performed, may take place in acontinuous or batch manner. The feed stream or streams introduced intothe cracking facility 70 can be in the form of a predominantly gasstream, a predominantly liquid stream, or combinations thereof.

As shown in FIG. 8 a , a stream of pyrolysis gas 172 and/or pyrolysisoil 174 may be introduced into a cracker facility 70 along with or asthe cracker feed stream 136. In some embodiments, the cracker feedstream 119 can comprise at least 1, at least 5, at least 10, at least15, at least 20, at least 25, at least 30, at least 35, at least 40, atleast 45, at least 50, at least 55, at least 60, at least 65, at least70, at least 75, at least 80, at least 85, at least 90, or at least 95weight percent of pyrolysis gas, pyrolysis oil, or pyrolysis gas andpyrolysis oil combined, based on the total weight of the stream 119.Alternatively, or in addition, the cracker feed stream 119 can comprisenot more than 95, not more than 90, not more than 85, not more than 80,not more than 75, not more than 70, not more than 65, not more than 60,not more than 55, not more than 50, not more than 45, not more than 40,not more than 35, not more than 30, not more than 25, or not more than20 weight percent of pyrolysis gas, pyrolysis oil, or a combination ofpyrolysis gas and pyrolysis oil, based on the total weight of the stream119, or it can include these components in an amount in the range offrom 1 to 95 weight percent, 5 to 90 weight percent, or to 85 percent,based on the total weight of the stream 119.

In some embodiments, the cracker feed stream 119 can include at least 5,at least 10, at least 15, at least 20, at least 25, at least 30, atleast 35, at least 40, at least 45, at least 50, at least 55, at least60, at least 65, at least 70, at least 75, at least 80, at least 85, atleast 90, or at least 95 weight percent and/or not more than 95, notmore than 90, not more than 85, not more than 80, not more than 75, notmore than 70, not more than 65, not more than 60, not more than 55, notmore than 50, not more than 45, not more than 40, not more than 35, notmore than 30, not more than 25, or not more than 20 weight percent of ahydrocarbon feed other than pyrolysis gas and pyrolysis oil, based onthe total weight of the cracker feed stream 119, or it can include ahydrocarbon feed other than pyrolysis gas and pyrolysis oil in an amountof from 5 to 95 weight percent, 10 to 90 weight percent, or 15 to 85weight percent, based on the total weight of the cracker feed stream119.

In an embodiment or in combination with any embodiment mentioned herein,the cracker feed stream 119 may comprise a predominantly C2 to C4hydrocarbon containing composition. As used herein, the term“predominantly C2 to C4 hydrocarbon,” refers to a stream or compositioncontaining at least 50 weight percent of C2 to C4 hydrocarboncomponents. Examples of specific types of C2 to C4 hydrocarbon streamsor compositions include propane, ethane, butane, and LPG. The crackerfeed stream 119 may comprise at least 50, or at least 55, or at least60, or at least 65, or at least 70, or at least 75, or at least 80, orat least 85, or at least 90, or at least 95, in each case wt. % based onthe total weight of the feed, and/or not more than 100, or not more than99, or not more than 95, or not more than 92, or not more than 90, ornot more than 85, or not more than 80, or not more than 75, or not morethan 70, or not more than 65, or not more than 60, in each case weightpercent C2 to C4 hydrocarbons or linear alkanes, based on the totalweight of the feed. The cracker feed stream 119 can comprisepredominantly propane, predominantly ethane, predominantly butane, or acombination of two or more of these components.

In an embodiment or in combination with any embodiment mentioned herein,the cracker feed stream 119 may comprise a predominantly C5 to C22hydrocarbon containing composition. As used herein, “predominantly C5 toC22 hydrocarbon” refers to a stream or composition comprising at least50 weight percent of C5 to C22 hydrocarbon components. Examples includegasoline, naphtha, middle distillates, diesel, kerosene.

In an embodiment or in combination with any embodiment mentioned herein,the cracker feed stream 119 may comprise at least 20, or at least 25, orat least 30, or at least 35, or at least 40, or at least 45, or at least50, or at least 55, or at least 60, or at least 65, or at least 70, orat least 75, or at least 80, or at least 85, or at least 90, or at least95, in each case wt. % and/or not more than 100, or not more than 99, ornot more than 95, or not more than 92, or not more than 90, or not morethan 85, or not more than 80, or not more than 75, or not more than 70,or not more than 65, or not more than 60, in each case weight percent C5to C22, or C5 to C20 hydrocarbons, based on the total weight of thestream, or it can include C5 to C22 in an amount in the range of from 20to 100 weight percent, 25 to 95 weight percent, or 30 to 85 weightpercent, based on the total weight of the stream.

In an embodiment or in combination with any embodiment mentioned herein,the cracker feed stream 119 may have a C15 and heavier (C15+) content ofat least 0.5, or at least 1, or at least 2, or at least 5, in each caseweight percent and/or not more than 40, or not more than 35, or not morethan 30, or not more than 25, or not more than 20, or not more than 18,or not more than 15, or not more than 12, or not more than 10, or notmore than 5, or not more than 3, in each case weight percent, based onthe total weight of the feed, or it can be in the range of from 0.5 to40 weight percent, 1 to 35 weight percent, or 2 to 30 weight percent,based on the total weight of the stream.

In an embodiment or in combination with any embodiment mentioned herein,the feed to the cracker furnace can comprise vacuum gas oil (VGO),hydrogenated vacuum gas oil (HVGO), or atmospheric gas oil (AGO). Thecracker feed stream 119 can comprise at least 5, at least 10, at least15, at least 20, at least 25, at least 30, at least 35, at least 40, atleast 45, at least 50, at least 55, at least 60, at least 65, at least70, at least 75, at least 80, at least 85, or at least 90 and/or notmore than 99, not more than 95, not more than 90, not more than 85, notmore than 80, not more than 75, not more than 70, not more than 65, notmore than 60, not more than 55, or not more than 50 weight percent of atleast one gas oil, based on the total weight of the stream, or it can bepresent in an amount in the range of from 5 to 99 weight percent, 10 to90 weight percent, or 15 to 85 weight percent, or 5 to 50 weightpercent, based on the total weight of the stream 119.

As shown in FIG. 8 a , the cracker feed stream 119 is introduced into acracker furnace 720. Turning now to FIG. 8 b , a schematic diagram of acracker furnace 720 suitable for use in a chemical recycling facilityand/or cracker facility as described herein is shown. As shown in FIG. 8b , the cracking furnace 720 can include a convection section 746, aradiant section 748, and a cross-over section 750 located between theconvection 746 and radiant sections 748. The convection section 746 isthe portion of the furnace that receives heat from hot flue gases andincludes a bank of tubes or coils 752 through which a cracker streampasses. In the convection section 746, the cracker stream is heated byconvection from the hot flue gasses passing therethrough. Although shownin FIG. 8 b as including horizontally-oriented convection section tubes752 a and vertically-oriented radiant section tubes 752 b, it should beunderstood that the tubes can be configured in any suitableconfiguration. For example, the convection section tubes 752 a may bevertical. The radiant section tubes 752 b may be horizontal.Additionally, although shown as a single tube, the cracker furnace 720may comprise one or more tubes or coils that may include at least onesplit, bend, U, elbow, or combinations thereof. When multiple tubes orcoils are present, such may be arranged in parallel and/or in series.

The radiant section 748 is the section of the furnace 720 into whichheat is transferred into the heater tubes primarily by radiation fromthe high-temperature gas. The radiant section 748 also includes aplurality of burners 756 for introducing heat into the lower portion ofthe furnace 720. The furnace 720 includes a fire box 754 which surroundsand houses the tubes 752 b within the radiant section 748 and into whichthe burners 756 are oriented. The cross-over section 750 includes pipingfor connecting the convection 746 and radiant 748 sections and maytransfer the heated cracker stream from one section to the other withinor external to the interior of the furnace 720.

As hot combustion gases ascend upwardly through the furnace stack, thegases may pass through the convection section 746, wherein at least aportion of the waste heat may be recovered and used to heat the crackerstream passing through the convection section 746. The cracking furnace720 may have a single convection (preheat) section and a single radiantsection, while, in other embodiments, the furnace may include two ormore radiant sections sharing a common convection section. At least oneinduced draft (I.D.) fan 760 near the stack may control the flow of hotflue gas and heating profile through the furnace 720, and one or moreheat exchangers 761 may be used to cool the furnace effluent. A liquidquench (not shown) may be used in addition to, or alternatively with,the exchanger 761 (e.g., transfer line heat exchanger or TLE) on theoutlet of the furnace shown in FIG. 8 b for cooling the crackedolefin-containing effluent 125.

In an embodiment or in combination with any embodiment mentioned herein,the cracker facility 70 may comprise a single cracking furnace, or itcan have at least 2, or at least 3, or at least 4, or at least 5, or atleast 6, or at least 7, or at least 8 or more cracking furnaces operatedin parallel. Any one or each furnace(s) may be gas cracker, or a liquidcracker, or a split furnace. The furnace can be a gas cracker receivinga cracker feed stream containing at least 50 wt. %, or at least 75 wt.%, or at least 85 wt. % or at least 90 wt. % ethane, propane, LPG, or acombination thereof through the furnace, or through at least one coil ina furnace, or through at least one tube in the furnace, based on theweight of all cracker feed to the furnace.

In an embodiment or in combination with any embodiment mentioned herein,the cracking furnace 720 can be a liquid or naphtha cracker receiving acracker feed stream containing at least 50 wt. %, or at least 75 wt. %,or at least 85 wt. % liquid (when measured at 25° C. and 1 atm)hydrocarbons having a carbon number from C5-C22.

In an embodiment or in combination with any embodiment mentioned herein,the cracker feed stream 119 can be cracked in a gas furnace. A gasfurnace is a furnace having at least one coil which receives (oroperated to receive or configured to receive), at the inlet of the coilat the entrance to the convection zone, a predominately vapor-phase feed(more than 50% of the weight of the feed is vapor) (“gas coil”). The gascoil can receive a predominately C2-C4 feedstock, or a predominately aC2-C3 feedstock, to the inlet of the coil in the convection section, oralternatively, having at least one coil receiving more than 50 wt. %ethane and/or more than 50% propane and/or more than 50% LPG, or in anyone of these cases at least 60 wt. %, or at least 70 wt. %, or at least80 wt. %, based on the weight of the cracker feed to the coil, oralternatively based on the weight of the cracker feed to the convectionzone.

The gas furnace may have more than one gas coil. In an embodiment or incombination with any embodiment mentioned herein, at least 25% of thecoils, or at least 50% of the coils, or at least 60% of the coils, orall the coils in the convection zone or within a convection box of thefurnace are gas coils. The gas coil receives, at the inlet of the coilat the entrance to the convection zone, a vapor-phase feed in which atleast 60 wt. %, or at least 70 wt. %, or at least 80 wt. %, or at least90 wt. %, or at least 95 wt. %, or at least 97 wt. %, or at least 98 wt.%, or at least 99 wt. %, or at least 99.5 wt. %, or at least 99.9 wt. %of feed is vapor.

In an embodiment or in combination with any embodiment mentioned herein,the feed stream can be cracked in a split furnace. A split furnace is atype of gas furnace. A split furnace contains at least one gas coil andat least one liquid coil within the same furnace, or within the sameconvection zone, or within the same convection box. A liquid coil is acoil which receives, at the inlet of coil at the entrance to theconvection zone, a predominately liquid phase feed (more than 50% of theweight of the feed is liquid) (“liquid coil”).

In an embodiment or in combination with any embodiment mentioned herein,the cracker feed stream 119 can be cracked in a thermal gas cracker.

In an embodiment or in combination with any embodiment mentioned herein,the cracker feed stream 119 can be cracked in a thermal steam gascracker in the presence of steam. Steam cracking refers to thehigh-temperature cracking (decomposition) of hydrocarbons in thepresence of steam. When present, steam may be introduced via line 121shown in FIG. 8 b.

In an embodiment or in combination with any embodiment mentioned herein,when two or more streams from the chemical recycling facility 10 shownin FIG. 1 are combined with another of the streams from the facility 10to form the cracker feed stream 119, such a combination may occurupstream of, or within, the cracking furnace 720. Alternatively, thedifferent feed streams may be introduced separately into the furnace720, and may pass through a portion, or all, of the furnace 720simultaneously while being isolated from one another by feeding intoseparate tubes within the same furnace 720 (e.g., a split furnace).Alternatively, at least a portion of the stream or streams from thechemical recycling facility may be introduced into the cracker facilityat a location downstream of the cracker furnace, but upstream of one ormore pieces of equipment in the separation facility.

The heated cracker stream 119 then passes through the cracking furnace720, wherein the hydrocarbon components therein are thermally cracked toform lighter hydrocarbons, including olefins such as ethylene,propylene, and/or butadiene. The residence time of the cracker streamthe furnace 720 can be at least 0.15, or at least 0.2, or at least 0.25,or at least 0.3, or at least 0.35, or at least 0.4, or at least 0.45, ineach case seconds and/or not more than 2, or not more than 1.75, or notmore than 1.5, or not more than 1.25, or not more than 1, or not morethan 0.9, or not more than 0.8, or not more than 0.75, or not more than0.7, or not more than 0.65, or not more than 0.6, or not more than 0.5,in each case seconds, or it can be in the range of from 0.15 to 2seconds, 0.20 to 1.75 seconds, or 0.25 to 1.5 seconds.

The temperature of the cracked olefin-containing effluent 125 withdrawnfrom the furnace outlet can be at least 640, or at least 650, or atleast 660, or at least 670, or at least 680, or at least 690, or atleast 700, or at least 720, or at least 730, or at least 740, or atleast 750, or at least 760, or at least 770, or at least 780, or atleast 790, or at least 800, or at least 810, or at least 820, in eachcase ° C. and/or not more than 1000, or not more than 990, or not morethan 980, or not more than 970, or not more than 960, or not more than950, or not more than 940, or not more than 930, or not more than 920,or not more than 910, or not more than 900, or not more than 890, or notmore than 880, or not more than 875, or not more than 870, or not morethan 860, or not more than 850, or not more than 840, or not more than830, in each case ° C., in the range of from 730 to 900° C., 750 to 875°C., or 750 to 850° C.

In an embodiment or in combination with any embodiment mentioned herein,the yield of olefin—ethylene, propylene, butadiene, or combinationsthereof—can be at least 15, or at least 20, or at least 25, or at least30, or at least 35, or at least 40, or at least 45, or at least 50, orat least 55, or at least 60, or at least 65, or at least 70, or at least75, or at least 80, in each case percent. As used herein, the term“yield” refers to the mass of product produced from the mass offeedstock/mass of feedstock x 100%. The olefin-containing effluentstream comprises at least 30, or at least 40, or at least 50, or atleast 60, or at least 70, or at least 75, or at least 80, or at least85, or at least 90, or at least 95, or at least 97, or at least 99, ineach case weight percent of ethylene, propylene, or ethylene andpropylene, based on the total weight of the effluent stream.

In an embodiment or in combination with any embodiment mentioned herein,the olefin-containing effluent stream 125 can comprise at least 10, atleast 15, at least 20, at least 25, at least 30, at least 35, at least40, at least 45, at least 50, at least 55, at least 60, at least 65, atleast 70, at least 75, at least 80, at least 85, or at least 90 weightpercent of C2 to C4 olefins. The stream 125 may comprise predominantlyethylene, predominantly propylene, or predominantly ethylene andpropylene, based on the total weight of the olefin-containing effluentstream 125. The weight ratio of ethylene-to-propylene in theolefin-containing effluent stream 125 can be at least 0.2:1, at least0.3:1, at least 0.4:1, at least 0.5:1, at least 0.6:1, at least 0.7:1,at least 0.8:1, at least 0.9:1, at least 1:1, at least 1.1:1, at least1.2:1, at least 1.3:1, at least 1.4:1, at least 1.5:1, at least 1.6:1,at least 1.7:1, at least 1.8:1, at least 1.9:1, or at least 2:1 and/ornot more than 3:1, not more than 2.9:1, not more than 2.8:1, not morethan 2.7:1, not more than 2.5:1, not more than 2.3:1, not more than2.2:1, not more than 2.1:1, not more than 2:1, not more than 1.7:1, notmore than 1.5:1, or not more than 1.25:1.

Turning again to FIG. 8 a , in an embodiment or in combination with anyembodiment mentioned herein, when introduced into the cracker facility70, the pyrolysis gas 172 may be introduced into the inlet of thecracker furnace 720, or all or a portion of the pyrolysis gas may beintroduced downstream of the furnace outlet, at a location upstream ofor within the separation zone 740 of the cracker facility 70. Whenintroduced into or upstream of the separation zone 740, the pyrolysisgas can be introduced upstream of the last stage of compression, orprior to the inlet of at least one fractionation column in thefractionation section of the separation zone 740.

Prior to entering the cracker facility 70, in an embodiment or incombination with any embodiment mentioned herein, a stream of rawpyrolysis gas from a pyrolysis facility may undergo one or moreseparation steps to remove one or more components from the stream.Examples of such components can include, but are not limited to,halogens, aldehydes, oxygenated compounds, nitrogen-containingcompounds, sulfur-containing compounds, carbon dioxide, water, vaporizedmetals, and combinations thereof. The pyrolysis gas stream 172introduced into the cracker facility 70 comprises at least 0.1, at least0.5, at least 1, at least 1.5, at least 2, at least 2.5, at least 3, atleast 3.5, at least 4, at least 4.5, or at least 5 and/or not more than30, not more than 25, not more than 20, not more than 15, not more than10, not more than 5, not more than 3, not more than 2, or not more than1 weight percent of one or more aldehyde components, based on the totalweight of the pyrolysis gas stream 172.

In an embodiment or in combination with any embodiment mentioned herein,the total ethylene content of the pyrolysis gas stream 172 can be atleast 1, at least 2, at least 5, at least 7, at least 10, at least 15,at least 20, at least 25, or at least 30 weight percent and/or not morethan 60, not more than 55, not more than 50, not more than 45, not morethan 40, or not more than 35 weight percent, based on the total weightof the stream 172. Alternatively, or in addition, the total propylenecontent of the pyrolysis gas stream 172 can be at least 1, at least 2,at least 5, at least 7, at least 10, at least 15, at least 20, at least25, or at least 30 weight percent and/or not more than 60, not more than55, not more than 50, not more than 45, not more than 40, or not morethan 35 weight percent, based on the total weight of the stream 172. Thecombined amount of ethylene and propylene in the pyrolysis gas stream172 can be at least 2, at least 5, at least 10, at least 15, at least20, at least 25, at least 30, at least 35, at least 40, or at least 45weight percent and/or not more than 85, not more than 80, not more than75, not more than 70, not more than 65, not more than 60, not more than55, not more than 50, or not more than 45 weight percent, based on thetotal weight of the stream.

Upon exiting the cracker furnace outlet, the olefin-containing effluentstream 125 may be cooled rapidly (e.g., quenched) in order to preventproduction of large amounts of undesirable by-products and to minimizefouling in downstream equipment. In an embodiment or in combination withany embodiment mentioned herein, the temperature of theolefin-containing effluent from the furnace can be reduced by 35 to 485°C., 35 to 375° C., or 90 to 550° C. to a temperature of 500 to 760° C.during the quench or cooling step.

The resulting cooled effluent stream can be then separated in avapor-liquid separator, and the vapor can be compressed in a gascompressor having, for example, between 1 and 5 compression stages withoptional inter-stage cooling and liquid removal. The pressure of the gasstream at the outlet of the first set of compression stages is in therange of from 7 to 20 bar gauge (barg), 8.5 to 18 barg, or 9.5 to 14barg. The resulting compressed stream is then treated for removal ofacid gases, including halogens, CO, CO₂, and H₂S by contact with an acidgas removal agent. Examples of acid gas removal agents can include, butare not limited to, caustic and various types of amines. In anembodiment or in combination with any embodiment mentioned herein, asingle contactor may be used, while, in other embodiments, a dual columnabsorber-stripper configuration may be employed.

The treated compressed olefin-containing stream may then be furthercompressed in another compressor, optionally with inter-stage coolingand liquid separation. The resulting compressed stream, which has apressure in the range of 20 to 50 barg, 25 to 45 barg, or 30 to 40 barg.Any suitable moisture removal method can be used including, for example,molecular sieves or other similar process. The resulting stream may thenbe passed to the fractionation section, wherein the olefins and othercomponents may be separated in to various high-purity product orintermediate streams. In some embodiments, all or a portion of thepyrolysis gas may be introduced prior to and/or after one or more stagesof the second compressor. Similarly, the pressure of the pyrolysis gasis within 20, within 50, within 100, or within 150 psi of the pressureof the stream with which it is being combined.

In an embodiment or in combination with any embodiment mentioned herein,a feed stream from the quench section may be introduced into at leastone column within a fractionation section of the separation zone. Asused herein, the term “fractionation” refers to the general process ofseparating two or more materials having different boiling points.Examples of equipment and processes that utilize fractionation include,but are not limited to, distillation, rectification, stripping, andvapor-liquid separation (single stage).

In an embodiment or in combination with any embodiment mentioned herein,the fractionation section of the cracker facility may include one ormore of a demethanizer, a deethanizer, a depropanizer, an ethylenesplitter, a propylene splitter, a debutanizer, and combinations thereof.As used herein, the term “demethanizer,” refers to a column whose lightkey component is methane. Similarly, “deethanizer,” and “depropanizer,”refer to columns with ethane and propane as the light key component,respectively.

Any suitable arrangement of columns may be used so that thefractionation section provides at least one olefin product stream and atleast one paraffin stream. In an embodiment or in combination with anyembodiment mentioned herein, the fractionation section can provide atleast two olefin streams, such as ethylene and propylene, and at leasttwo paraffin streams, such as ethane and propane, as well as additionalstreams including, for example, methane and lighter components andbutane and heavier components.

In an embodiment or in combination with any embodiment mentioned herein,the olefin stream withdrawn from the fractionation section can compriseat least 50, at least 55, at least 60, at least 65, at least 70, atleast 75, at least 80, at least 85, at least 90, or at least 95 weightpercent and/or not more than 100, not more than 99, not more than 97,not more than 95, not more than 90, not more than 85, or not more than80 weight percent of olefins, based on the total weight of the olefinstream. The olefins can be predominantly ethylene or predominantlypropylene. The olefin stream can comprise at least 50, at least 55, atleast 60, at least 65, at least 70, at least 75, at least 80, at least85, at least 90, or at least 95 weight percent and/or not more than 99,not more than 97, not more than 95, not more than 90, not more than 85,not more than 80, not more than 75, not more than 70, or not more than65 weight percent of ethylene, based on the total weight of olefins inthe olefin stream. The olefin stream may comprise at least 20, at least25, at least 30, at least 35, at least 40, at least 45, at least 50, atleast 55, or at least 60 weight percent and/or not more than 80, notmore than 75, not more than 70, not more than 65, not more than 60, notmore than 55, not more than 50, or not more than 45 weight percent ofethylene, based on the total weight of the olefin stream, or it can bepresent in an amount in the range of from 20 to 80 weight percent, 25 to75 weight percent, or 30 to 70 weight percent, based on the total weightof the olefin stream.

Alternatively, or in addition, the olefin stream can comprise at least50, at least 55, at least 60, at least 65, at least 70, at least 75, atleast 80, at least 85, at least 90, or at least 95 weight percent and/ornot more than 99, not more than 97, not more than 95, not more than 90,not more than 85, not more than 80, not more than 75, not more than 70,or not more than 65 weight percent of propylene, based on the totalweight of olefins in the olefin stream. In an embodiment or incombination with any embodiment mentioned herein, the olefin stream maycomprise at least 20, at least 25, at least 30, at least 35, at least40, at least 45, at least 50, at least 55, or at least 60 weight percentand/or not more than 80, not more than 75, not more than 70, not morethan 65, not more than 60, not more than 55, not more than 50, or notmore than 45 weight percent of propylene, based on the total weight ofthe olefin stream, or it can be present in an amount in the range offrom 20 to 80 weight percent, 25 to 75 weight percent, or 30 to 70weight percent, based on the total weight of the olefin stream.

As the compressed stream passes through the fractionation section, itpassed through a demethanizer column, wherein the methane and lighter(CO, CO₂, H₂) components are separated from the ethane and heaviercomponents. The demethanizer can be operated at a temperature of atleast −145, or at least −142, or at least −140, or at least −135, ineach case ° C. and/or not more than −120, not more than −125, not morethan −130, not more than −135° C. The bottoms stream from thedemethanizer column includes at least 50, or at least 55, or at least60, or at least 65, or at least 70, or at least 75, or at least 80, orat least 85, or at least 90, or at least 95 or at least 99, in each casepercent of the total amount of ethane and heavier components.

In an embodiment or in combination with any embodiment mentioned herein,all or a portion of the stream introduced into the fractionation sectioncan be introduced into a deethanizer column, wherein the C2 and lightercomponents are separated from the C3 and heavier components byfractional distillation. The deethanizer can be operated with anoverhead temperature of at least −35, or at least −30, or at least −25,or at least −20, in each case ° C. and/or not more than −5, not morethan −10, not more than −15, not more than −20° C., and an overheadpressure of at least 3, or at least 5, or at least 7, or at least 8, orat least 10, in each case barg and/or not more than 20, or not more than18, or not more than 17, or not more than 15, or not more than 14, ornot more than 13, in each case barg. The deethanizer column recovers atleast 60, or at least 65, or at least 70, or at least 75, or at least80, or at least 85, or at least 90, or at least 95, or at least 97, orat least 99, in each case percent of the total amount of C2 and lightercomponents introduced into the column in the overhead stream. Theoverhead stream removed from the deethanizer column comprises at least50, or at least 55, or at least 60, or at least 65, or at least 70, orat least 75, or at least 80, or at least 85, or at least 90, or at least95, in each case weight percent of ethane and ethylene, based on thetotal weight of the overhead stream.

In an embodiment or in combination with any embodiment mentioned herein,the C2 and lighter overhead stream from a deethanizer can be furtherseparated in an ethane-ethylene fractionator column (ethylenefractionator or ethylene splitter). In the ethane-ethylene fractionatorcolumn, an ethylene and lighter component stream can be withdrawn fromthe overhead of the column or as a side stream from the top half of thecolumn, while the ethane and any residual heavier components are removedin the bottoms stream. The ethylene fractionator may be operated at anoverhead temperature of at least −45, or at least −40, or at least −35,or at least −30, or at least −25, or at least −20, in each case ° C.and/or not more than −15, or not more than −20, or not more than −25, ineach case ° C., and an overhead pressure of at least 10, or at least 12,or at least 15, in each case barg and/or not more than 25, not more than22, not more than 20 barg. The overhead stream, which may be enriched inethylene, can include at least 70, or at least 75, or at least 80, or atleast 85, or at least 90, or at least 95, or at least 97, or at least98, or at least 99, in each case weight percent ethylene, based on thetotal weight of the stream and may be sent to downstream processing unitfor further processing, storage, or sale.

The bottoms stream from the ethane-ethylene fractionator may include atleast 40, or at least 45, or at least 50, or at least 55, or at least60, or at least 65, or at least 70, or at least 75, or at least 80, orat least 85, or at least 90, or at least 95, or at least 98, in eachcase weight percent ethane, based on the total weight of the bottomsstream. All or a portion of the recovered ethane may be recycled to theinlet of the cracker furnace as additional feedstock, alone or incombination with the pyrolysis oil and/or pyrolysis gas, as discussedpreviously.

In some embodiments, at least a portion of the compressed stream may beseparated in a depropanizer, wherein C3 and lighter components areremoved as an overhead vapor stream, while C4 and heavier componentsexit the column in the liquid bottoms. The depropanizer can be operatedwith an overhead temperature of at least 20, or at least 35, or at least40, in each case ° C. and/or not more than 70, 65, 60, 55° C., and anoverhead pressure of at least 10, or at least 12, or at least 15, ineach case barg and/or not more than 20, or not more than 17, or not morethan 15, in each case barg. The depropanizer column recovers at least60, or at least 65, or at least 70, or at least 75, or at least 80, orat least 85, or at least 90, or at least 95, or at least 97, or at least99, in each case percent of the total amount of C3 and lightercomponents introduced into the column in the overhead stream. In anembodiment or in combination with any embodiment mentioned herein, theoverhead stream removed from the depropanizer column comprises at leastor at least 50, or at least 55, or at least 60, or at least 65, or atleast 70, or at least 75, or at least 80, or at least 85, or at least90, or at least 95, or at least 98, in each case weight percent ofpropane and propylene, based on the total weight of the overhead stream.

In an embodiment or in combination with any embodiment mentioned herein,the overhead stream from the depropanizer may be introduced into apropane-propylene fractionator (propylene fractionator or propylenesplitter), wherein the propylene and any lighter components are removedin the overhead stream and the propane and any heavier components exitthe column in the bottoms stream. The propylene fractionator may beoperated at an overhead temperature of at least 20, or at least 25, orat least 30, or at least 35, in each case ° C. and/or not more than 55,not more than 50, not more than 45, not more than 40° C., and anoverhead pressure of at least 12, or at least 15, or at least 17, or atleast 20, in each case barg and/or not more than 20, or not more than17, or not more than 15, or not more than 12, in each case barg. Theoverhead stream, which is enriched in propylene, can include at least70, or at least 75, or at least 80, or at least 85, or at least 90, orat least 95, or at least 97, or at least 98, or at least 99, in eachcase weight percent propylene, based on the total weight of the streamand may be sent to downstream processing unit for further processing,storage, or sale.

The bottoms stream from the propane-propylene fractionator may includeat least 40, or at least 45, or at least 50, or at least 55, or at least60, or at least 65, or at least 70, or at least 75, or at least 80, orat least 85, or at least 90, or at least 95, or at least 98, in eachcase weight percent propane, based on the total weight of the bottomsstream. All or a portion of the recovered propane may be recycled to thecracker furnace as additional feedstock, alone or in combination withpyrolysis oil and/or pyrolysis gas, as discussed previously.

In an embodiment or in combination with any embodiment mentioned herein,at least a portion of the compressed stream may be sent to a debutanizercolumn for separating C4 and lighter components, including butenes,butanes and butadienes, from C5 and heavier (C5+) components. Thedebutanizer can be operated with an overhead temperature of at least 20,or at least 25, or at least 30, or at least 35, or at least 40, in eachcase ° C. and/or not more than 60, or not more than 65, or not more than60, or not more than 55, or not more than 50, in each case ° C. and anoverhead pressure of at least 2, or at least 3, or at least 4, or atleast 5, in each case barg and/or not more than 8, or not more than 6,or not more than 4, or not more than 2, in each case barg. Thedebutanizer column recovers at least 60, or at least 65, or at least 70,or at least 75, or at least 80, or at least 85, or at least 90, or atleast 95, or at least 97, or at least 99, in each case percent of thetotal amount of C4 and lighter components introduced into the column inthe overhead stream.

In an embodiment or in combination with any embodiment mentioned herein,the overhead stream removed from the debutanizer column comprises atleast 30, or at least 35, or at least 40, or at least 45, or at least50, or at least 55, or at least 60, or at least 65, or at least 70, orat least 75, or at least 80, or at least 85, or at least 90, or at least95, in each case weight percent of butadiene, based on the total weightof the overhead stream. The bottoms stream from the debutanizer includesmainly C5 and heavier components, in an amount of at least 50, or atleast 60, or at least 70, or at least 80, or at least 90, or at least 95weight percent, based on the total weight of the stream. The debutanizerbottoms stream may be sent for further separation, processing, storage,sale or use. In an embodiment or in combination with any embodimentmentioned herein, the overhead stream from the debutanizer, or the C4s,can be subjected to any conventional separation methods such asextraction or distillation processes to recover a more concentratedstream of butadiene.

In an embodiment or in combination with any embodiment mentioned herein,at least a portion of one or more of the above streams may be introducedinto one or more of the facilities shown in FIG. 1 , while, in otherembodiments, all or a portion of the streams withdrawn from theseparation zone of the cracking facility may be routed to furtherseparation and/or storage, transportation, sale, and/or use.

Partial Oxidation (POX) Gasification

In an embodiment or in combination with any embodiment mentioned herein,the chemical recycling facility may also comprise a partial oxidation(POX) gasification facility. As used herein, the term “partialoxidation” refers to high temperature conversion of a carbon-containingfeed into syngas (carbon monoxide, hydrogen, and carbon dioxide), wherethe conversion is carried out in the presence of a sub-stoichiometricamount of oxygen. The conversion can be of a hydrocarbon-containing feedand can be carried out with an amount of oxygen that is less than thestoichiometric amount of oxygen needed for complete oxidation of thefeed—i.e., all carbon oxidized to carbon dioxide and all hydrogenoxidized to water. The reactions occurring within a partial oxidation(POX) gasifier include conversion of a carbon-containing feed intosyngas, and specific examples include, but are not limited to partialoxidation, water gas shift, water gas—primary reactions, Boudouard,oxidation, methanation, hydrogen reforming, steam reforming, and carbondioxide reforming. The feed to POX gasification can include solids,liquids, and/or gases. A “partial oxidation facility” or “POXgasification facility” is a facility that includes all equipment, lines,and controls necessary to carry out POX gasification of waste plasticand feedstocks derived therefrom.

In the POX gasification facility, the feed stream may be converted tosyngas in the presence of a sub-stoichiometric amount of oxygen. In anembodiment or in combination with any embodiment mentioned herein, thefeed stream to the POX gasification facility may comprise one or more ofa PO-enriched waste plastic, at least one solvolysis coproduct stream, apyrolysis stream (including pyrolysis gas, pyrolysis oil, and/orpyrolysis residue), and at least one stream from the cracking facility.One or more of these streams may be introduced into the POX gasificationfacility continuously or one or more of these streams may be introducedintermittently. When multiple types of feed streams are present, eachmay be introduced separately, or all or a portion of the streams may becombined so that the combined stream may be introduced into the POXgasification facility. The combining, when present, may take place in acontinuous or batch manner. The feed stream can be in the form of a gas,a liquid or liquified plastic, solids (usually comminuted), or a slurry.

The POX gasification facility includes at least one POX gasificationreactor. An exemplary POX gasification reactor 52 is shown in FIG. 9 .The POX gasification unit may comprise a gas-fed, a liquid-fed, or asolid-fed reactor (or gasifier). In an embodiment or in combination withany embodiment mentioned herein, the POX gasification facility mayperform liquid-fed POX gasification. As used herein, “liquid-fed POXgasification” refers to a POX gasification process where the feed to theprocess comprises predominately (by weight) components that are liquidat 25° C. and 1 atm. Additionally, or alternatively, POX gasificationunit may perform gas-fed POX gasification. As used herein, “gas-fed POXgasification” refers to a POX gasification process where the feed to theprocess comprises predominately (by weight) components that are gaseousat 25° C. and 1 atm.

Additionally, or alternatively, POX gasification unit may conductsolid-fed POX gasification. As used herein, “solid-fed POX gasification”refers to a POX gasification process where the feed to the processcomprises predominately (by weight) components that are solid at 25° C.and 1 atm.

Gas-fed, liquid-fed, and solid-fed POX gasification processes can beco-fed with lesser amounts of other components having a different phaseat 25° C. and 1 atm. Thus, gas-fed POX gasifiers can be co-fed withliquids and/or solids, but only in amounts that are less (by weight)than the amount of gasses fed to the gas-phase POX gasifier; liquid-fedPOX gasifiers can be co-fed with gasses and/or solids, but only inamounts (by weight) less than the amount of liquids fed to theliquid-fed POX gasifier; and solid-fed POX gasifiers can be co-fed withgasses and/or liquids, but only in amounts (by weight) less than theamount of solids fed to the solid-fed POX gasifier.

In an embodiment or in combination with any embodiment mentioned herein,the total feed to a gas-fed POX gasifier can comprise at least 60, atleast 70, at least 80, at least 90, or at least 95 weight percent ofcomponents that are gaseous at 25° C. and 1 atm; the total feed to aliquid-fed POX gasifier can comprise at least 60, at least 70, at least80, at least 90, or at least 95 weight percent of components that areliquid at 25° C. and 1 atm; and the total feed to a solid-fed POXgasifier can comprise at least 60, at least 70, at least 80, at least90, or at least 95 weight percent of components that are solids at 25°C. and 1 atm.

As generally shown in FIG. 9 , the gasification feeds stream 116 may beintroduced into a gasification reactor along with an oxidizing agentstream 180. The feedstock stream 116 and the oxidizing agent stream 180may be sprayed through an injector assembly into a pressurizedgasification zone having, for example, a pressure, typically at least500, at least 600, at least 800, or at least 1,000 psig, (or at least35, at least 40, at least 55, or at least 70 barg).

In an embodiment or in combination with any embodiment mentioned herein,the oxidizing agent in stream 180 comprises an oxidizing gas that caninclude air, oxygen-enriched air, or molecular oxygen (O2). Theoxidizing agent can comprise at least 25, at least 35, at least 40, atleast 50, at least 60, at least 70, at least 80, at least 90, at least95, at least 97, at least 99, or at least 99.5 mole percent of molecularoxygen based on the total moles of all components in the oxidizing agentstream 180 injected into the reaction (combustion) zone of thegasification reactor 52. The particular amount of oxygen as supplied tothe reaction zone can be sufficient to obtain near or maximum yields ofcarbon monoxide and hydrogen obtained from the gasification reactionrelative to the components in the feed stream 116, considering theamount relative to the feed stream, and the amount of feed charged, theprocess conditions, and the reactor design.

The oxidizing agent can include other oxidizing gases or liquids, inaddition to or in place of air, oxygen-enriched air, and molecularoxygen. Examples of such oxidizing liquids suitable for use as oxidizingagents include water (which can be added as a liquid or as steam) andammonia. Examples of such oxidizing gases suitable for use as oxidizingagents include carbon monoxide, carbon dioxide, and sulfur dioxide.

In an embodiment or in combination with any embodiment mentioned herein,an atomization enhancing fluid is fed to the gasification zone alongwith the feedstock and oxidizing agent. As used herein, the term“atomization enhancing fluid” refers to a liquid or gas operable toreduce viscosity to decrease dispersion energy, or increase energyavailable to assist dispersion. The atomization enhancing fluid may bemixed with the plastic-containing feedstock before the feedstock is fedinto the gasification zone or separately added to the gasification zone,for example to an injection assembly coupled with the gasificationreactor. In an embodiment or in combination with any embodimentmentioned herein, the atomization enhancing fluid is water and/or steam.However, in an embodiment or in combination with any embodimentmentioned herein, steam and/or water is not supplied to the gasificationzone.

an embodiment or in combination with any embodiment mentioned herein, agas stream enriched in carbon dioxide or nitrogen (e.g., greater thanthe molar quantity found in air, or at least 2, at least 5, at least 10,or at least 40 mole percent) is charged into the gasifier. These gasesmay serve as carrier gases to propel a feedstock to a gasification zone.Due to the pressure within the gasification zone, these carrier gasesmay be compressed to provide the motive force for introduction into thegasification zone. This gas stream may be compositionally the same as ordifferent than the atomization enhancing fluid. In one or moreembodiments, this gas stream also functions as the atomization enhancingfluid.

In an embodiment or in combination with any embodiment mentioned herein,a gas stream enriched in hydrogen (H2) (e.g., at least 1, at least 2, atleast 5, at least 10, at least 20, at least 30, at least 40, at least50, at least 60, at least 70, at least 80, or at least 90 mole percentis charged into the gasifier. Hydrogen may be added to affect thepartial oxidation reactions so as to control the resulting syngascomposition.

In an embodiment or in combination with any embodiment mentioned herein,no gas stream containing more than 0.01 or more than 0.02 mole percentof carbon dioxide is charged to the gasifier or gasification zone.Alternatively, no gas stream containing more than 77, more than 70, morethan 50, more than 30, more than 10, more than 5, or more than 3 molepercent nitrogen is charged to the gasifier or gasification zone.Furthermore, a gaseous hydrogen stream more than 0.1, more than 0.5,more than 1, or more than 5 mole percent hydrogen is not charged to thegasifier or to the gasification zone. Moreover, a stream of methane gascontaining more than 0.1, more than 0.5, more than 1, or more than 5mole percent methane is not charged to the gasifier or to thegasification zone. In certain embodiments, the only gaseous streamintroduced to the gasification zone is the oxidizing agent.

The gasification process can be a partial oxidation (POX) gasificationreaction, as described previously. Generally, to enhance the productionof hydrogen and carbon monoxide, the oxidation process involves partial,rather than complete, oxidization of the gasification feedstock and,therefore, may be operated in an oxygen-lean environment, relative tothe amount needed to completely oxidize 100 percent of the carbon andhydrogen bonds. In an embodiment or in combination with any embodimentmentioned herein, the total oxygen requirements for the gasifier may beat least 5, at least 10, at least 15, or at least 20 percent in excessof the amount theoretically required to convert the carbon content ofthe gasification feedstock to carbon monoxide. In general, satisfactoryoperation may be obtained with a total oxygen supply of to 80 percent inexcess of the theoretical requirements. For example, examples ofsuitable amounts of oxygen per pound of carbon may be in the range of0.4 to 3.0, 0.6 to 2.5, 0.9 to 2.5, or 1.2 to 2.5 pounds free oxygen perpound of carbon.

Mixing of the feedstock stream and the oxidizing agent may beaccomplished entirely within the reaction zone by introducing theseparate streams of feedstock and oxidizing agent so that they impingeupon each other within the reaction zone. In an embodiment or incombination with any embodiment mentioned herein, the oxidizing agentstream is introduced into the reaction zone of the gasifier as highvelocity to both exceed the rate of flame propagation and to improvemixing with the feedstock stream. In an embodiment or in combinationwith any embodiment mentioned herein, the oxidant may be injected intothe gasification zone in the range of 25 to 500, 50 to 400, or 100 to400 feet per second. These values would be the velocity of the gaseousoxidizing agent stream at the injector-gasification zone interface, orthe injector tip velocity. Mixing of the feedstock stream and theoxidizing agent may also be accomplished outside of the reaction zone.For example, in an embodiment or in combination with any embodimentmentioned herein, the feedstock, oxidizing agent, and/or atomizationenhancing fluid can be combined in a conduit upstream of thegasification zone or in an injection assembly coupled with thegasification reactor.

In an embodiment or in combination with any embodiment mentioned herein,the gasification feedstock stream, the oxidizing agent, and/or theatomization enhancing fluid can optionally be preheated to a temperatureof at least 200° C., at least 300° C., or at least 400° C. However, thegasification process employed does not require preheating the feedstockstream to efficiently gasify the feedstock and a pre-heat treatment stepmay result in lowering the energy efficiency of the process.

In an embodiment or in combination with any embodiment mentioned herein,the type of gasification technology employed may be a partial oxidationentrained flow gasifier that generates syngas. This technology isdistinct from fixed bed (alternatively called moving bed) gasifiers andfrom fluidized bed gasifiers. An exemplary gasifier that may be used indepicted in U.S. Pat. No. 3,544,291, the entire disclosure of which isincorporated herein by reference to the extent not inconsistent with thepresent disclosure. However, in an embodiment or in combination with anyembodiment mentioned herein, other types of gasification reactors mayalso be used within the scope of the present technology.

In an embodiment or in combination with any embodiment mentioned herein,the gasifier/gasification reactor can be non-catalytic, meaning that thegasifier/gasification reactor does not contain a catalyst bed and thegasification process is non-catalytic, meaning that a catalyst is notintroduced into the gasification zone as a discrete unbound catalyst.Furthermore, in an embodiment or in combination with any embodimentmentioned herein, the gasification process may not be a slagginggasification process; that is, operated under slagging conditions (wellabove the fusion temperature of ash) such that a molten slag is formedin the gasification zone and runs along and down the refractory walls.

In an embodiment or in combination with any embodiment mentioned herein,the gasification zone, and optionally all reaction zones in thegasifier/gasification reactor, may be operated at a temperature of atleast 1000° C., at least 1100° C., at least 1200° C., at least 1250° C.,or at least 1300° C. and/or not more than 2500° C., not more than 2000°C., not more than 1800° C., or not more than 1600° C. The reactiontemperature may be autogenous. Advantageously, the gasifier operating insteady state mode may be at an autogenous temperature and does notrequire application of external energy sources to heat the gasificationzone.

In an embodiment or in combination with any embodiment mentioned herein,the gasifier is a predominately gas fed gasifier.

In an embodiment or in combination with any embodiment mentioned herein,the gasifier is a non-slagging gasifier or operated under conditions notto form a slag.

In an embodiment or in combination with any embodiment mentioned herein,the gasifier may not be under negative pressure during operations, butrather can be under positive pressure during operation.

In an embodiment or in combination with any embodiment mentioned herein,the gasifier may be operated at a pressure within the gasification zone(or combustion chamber) of at least 200 psig (1.38 MPa), 300 psig (2.06MPa), 350 psig (2.41 MPa), 400 psig (2.76 MPa), 420 psig (2.89 MPa), 450psig (3.10 MPa), 475 psig (3.27 MPa), 500 psig (3.44 MPa), 550 psig(3.79 MPa), 600 psig (4.13 MPa), 650 psig (4.48 MPa), 700 psig (4.82MPa), 750 psig (5.17 MPa), 800 psig (5.51 MPa), 900 psig (6.2 MPa), 1000psig (6.89 MPa), 1100 psig (7.58 MPa), or 1200 psig (8.2 MPa).Additionally or alternatively, the gasifier may be operated at apressure within the gasification zone (or combustion chamber) of notmore than 1300 psig (8.96 MPa), 1250 psig (8.61 MPa), 1200 psig (8.27MPa), 1150 psig (7.92 MPa), 1100 psig (7.58 MPa), 1050 psig (7.23 MPa),1000 psig (6.89 MPa), 900 psig (6.2 MPa), 800 psig (5.51 MPa), or 750psig (5.17 MPa).

Examples of suitable pressure ranges include 300 to 1000 psig (2.06 to6.89 MPa), 300 to 750 psig (2.06 to 5.17 MPa), 350 to 1000 psig (2.41 to6.89 MPa), 350 to 750 psig (2.06 to 5.17 MPa), 400 to 1000 psig (2.67 to6.89 MPa), 420 to 900 psig (2.89 to 6.2 MPa), 450 to 900 psig (3.10 to6.2 MPa), 475 to 900 psig (3.27 to 6.2 MPa), 500 to 900 psig (3.44 to6.2 MPa), 550 to 900 psig (3.79 to 6.2 MPa), 600 to 900 psig (4.13 to6.2 MPa), 650 to 900 psig (4.48 to 6.2 MPa), 400 to 800 psig (2.67 to5.51 MPa), 420 to 800 psig (2.89 to 5.51 MPa), 450 to 800 psig (3.10 to5.51 MPa), 475 to 800 psig (3.27 to 5.51 MPa), 500 to 800 psig (3.44 to5.51 MPa), 550 to 800 psig (3.79 to 5.51 MPa), 600 to 800 psig (4.13 to5.51 MPa), 650 to 800 psig (4.48 to 5.51 MPa), 400 to 750 psig (2.67 to5.17 MPa), 420 to 750 psig (2.89 to 5.17 MPa), 450 to 750 psig (3.10 to5.17 MPa), 475 to 750 psig (3.27 to 5.17 MPa), 500 to 750 psig (3.44 to5.17 MPa), or 550 to 750 psig (3.79 to 5.17 MPa).

Generally, the average residence time of gases in the gasifier reactorcan be very short to increase throughput. Since the gasifier may beoperated at high temperature and pressure, substantially completeconversion of the feedstock to gases can occur in a very short timeframe. In an embodiment or in combination with any embodiment mentionedherein, the average residence time of the gases in the gasifier can benot more than 30, not more than 25, not more than 20, not more than 15,not more than 10, or not more than 7 seconds.

To avoid fouling downstream equipment from the gasifier, and the pipingin-between, the resulting raw syngas stream 127 may have a low or no tarcontent. In an embodiment or in combination with any embodimentmentioned herein, the syngas stream discharged from the gasifier maycomprise not more than 4, not more than 3, not more than 2, not morethan 1, not more than 0.5, not more than 0.2, not more than 0.1, or notmore than 0.01 weight percent of tar based on the weight of allcondensable solids in the syngas stream. For purposes of measurement,condensable solids are those compounds and elements that condense at atemperature of 15° C. and 1 atm. Examples of tar products includenaphthalenes, cresols, xylenols, anthracenes, phenanthrenes, phenols,benzene, toluene, pyridine, catechols, biphenyls, benzofurans,benzaldehydes, acenaphthylenes, fluorenes, naphthofurans,benzanthracenes, pyrenes, acephenanthrylenes, benzopyrenes, and otherhigh molecular weight aromatic polynuclear compounds. The tar contentcan be determined by GC-MSD.

Generally, the raw syngas stream 127 discharged from the gasificationvessel includes such gases as hydrogen, carbon monoxide, and carbondioxide and can include other gases such as methane, hydrogen sulfide,and nitrogen depending on the fuel source and reaction conditions.

In an embodiment or in combination with any embodiment mentioned herein,the raw syngas stream 127 (the stream discharged from the gasifier andbefore any further treatment by way of scrubbing, shift, or acid gasremoval) can have the following composition in mole percent on a drybasis and based on the moles of all gases (elements or compounds ingaseous state at 25° C. and 1 atm) in the raw syngas stream 127:

-   -   a hydrogen content in the range of 32 to 50 percent, or at least        33, at least 34, or at least 35 and/or not more than 50, not        more than 45, not more than 41, not more than 40, or not more        than 39 percent, or it can be in the range of 33 to 50 percent,        34 to 45 percent, or 35 to 41 percent, on a dry volume basis;    -   a carbon monoxide content of at least 40, at least 41, at least        42, or at least 43 and/or not more than 55, not more than 54,        not more than 53, or not more than 52 weight percent, based on        the total weight of the stream, or in the range of from 40 to 55        weight percent, 41 to 54 weight percent, or 42 to 53 weight        percent, based on the total weight of the stream on a dry basis;    -   a carbon dioxide content of at least 1%, at least 1.5%, at least        2%, at least 3%, at least 4%, at least 5%, at least 6%, or at        least 7% by volume and/or not more than 25%, not more than 20%,        not more than 15%, not more than 12%, not more than 11%, not        more than 10%, not more than 9%, not more than 8%, or not more        than 7% by volume on a dry basis;    -   a methane content of not more than 5000, not more than 2500, not        more than 2000, or not more than 1000 ppm by volume methane on a        dry basis;    -   a sulfur content of not more than 1000, not more than 100, not        more than 10, or not more than 1 ppm by weight (ppmw);    -   a soot content of at least 1000, or at least 5000 ppm and/or not        more than 50,000, not more than 20,000, or not more than 15,000        ppmw;    -   a halides content of not more than 1000, not more than 500, not        more than 200, not more than 100, or not more than 50 ppmw;    -   a mercury content of not more than 0.01, not more than 0.005, or        not more than 0.001 ppmw;    -   an arsine content of not more than 0.1 ppm, not more than 0.05,        or not more than 0.01 ppmw;    -   a nitrogen content of not more than 10,000, not more than 3000,        not more than 1000, or not more than 100 ppmw nitrogen;    -   an antimony content of at least 10 ppmw, at least 20 ppmw, at        least ppmw, at least 40 ppmw, or at least 50 ppmw, and/or not        more than 200 ppmw, not more than 180 ppmw, not more than 160        ppmw, not more than 150 ppmw, or not more than 130 ppmw; and/or    -   a titanium content of at least 10 ppmw, at least 25 ppmw, at        least 50 ppmw, at least 100 ppmw, at least 250 ppmw, at least        500 ppmw, or at least 1000 ppmw, and/or not more than 40,000        ppmw, not more than 30,000 ppmw, not more than 20,000 ppmw, not        more than 15,000 ppmw, not more than 10,000 ppmw, not more than        7,500 ppmw, or not more than 5,000 ppmw.

In an embodiment or in combination with any embodiment mentioned herein,the syngas comprises a molar hydrogen/carbon monoxide ratio of 0.7 to 2,0.7 to 1.5, 0.8 to 1.2, 0.85 to 1.1, or 0.9 to 1.05.

The gas components can be determined by Flame Ionization Detector GasChromatography (FID-GC) and Thermal Conductivity Detector GasChromatography (TCD-GC) or any other method recognized for analyzing thecomponents of a gas stream.

In an embodiment or in combination with any embodiment mentioned herein,the recycle content syngas can have a recycle content of at least 1, atleast 5, at least 10, at least 15, at least 20, at least 25, at least30, at least 35, at least 40, at least 45, at least 50, at least 55, atleast 60, at least 65, at least 70, at least 75, at least 80, at least85, at least 90, at least 95, or at least 99 weight percent, based onthe total weight of the syngas stream.

Energy Recovery

In an embodiment or in combination with any embodiment mentioned herein,the chemical recycling facility may also comprise an energy recoveryfacility. As used herein, an “energy recovery facility” is a facilitythat generates energy (i.e., thermal energy) from a feedstock viachemical conversion (e.g., combustion) of the feedstock. At least 5, atleast 10, at least 15, at least 20, at least 25, at least 30, or atleast 35 percent of the total energy generated from combustion can berecovered and used in one or more other processes and/or facilities.

In an embodiment or in combination with any embodiment mentioned herein,the feed stream introduced into the energy recovery facility 80 (FIG. 1) may comprise one or more of at least a portion of a PO-enriched wasteplastic, at least one solvolysis coproduct stream, at least a portion ofone or more of pyrolysis gas, pyrolysis oil, and pyrolysis residue,and/or one or more other streams from within the chemical recyclingfacility. In an embodiment or in combination with any embodimentmentioned herein, one or more of these streams may be introduced intothe energy recovery facility continuously or one or more of thesestreams may be introduced intermittently. When multiple types of feedstreams are present, each may be introduced separately, or all or aportion of the streams may be combined so that the combined stream maybe introduced into the energy recovery facility. The combining, whenpresent, may take place in a continuous or batch manner. The feed streammay include solids, a melt, a predominantly liquid stream, a slurry, apredominantly gas stream, or combinations thereof.

Any type of energy recovery facility may be used. In some embodiments,the energy recovery facility may comprise at least one furnace orincinerator. The incinerator may be gas-fed, liquid-fed, or solid-fed,or may be configured to accept a gas, liquid, or solid. The incineratoror furnace may be configured to thermally combust at least a portion ofthe hydrocarbon components in the feed stream with an oxidizing agent.In an embodiment or in combination with any embodiment mentioned herein,the oxidizing agent comprises at least 5, at least 10, at least 15, atleast 20, or at least 25 and/or not more than 95, not more than 90, notmore than 80, not more than 70, not more than 65, not more than 60, notmore than 55, not more than 50, not more than 45, not more than 40, notmore than 35, not more than 30, or not more than 25 mole percent oxygen,based on the total moles of oxidizing agent. Other components of theoxidizing agent can include, for example, nitrogen, or carbon dioxide.In other embodiments, the oxidizing agent comprises air.

In the energy recovery facility, at least 50, at least 60, at least 70,at least 80, at least 90, or at least 95 weight percent of the feedintroduced therein can be combusted to form energy and combustion gasessuch as water, carbon monoxide, carbon dioxide, and combinationsthereof. In some embodiments, at least a portion of the feed may betreated to remove compounds such as sulfur and/or nitrogen-containingcompounds, to minimize the amount of nitrogen and sulfur oxides in thecombustion gases.

In an embodiment or in combination with any embodiment mentioned herein,at least a portion of the energy generated may be used to directly orindirectly heat a process stream. For example, at least a portion of theenergy may be used to heat water to form steam, or to heat steam andform superheated steam. At least a portion of the energy generated maybe used to heat a stream of heat transfer medium (such as, for example,THERMINOL®), which itself, when warmed, may be used to transfer heat toone or more process streams. At least a portion of the energy may beused to directly heat a process stream.

In some embodiments, the process stream heated with at least a portionof the energy from the energy recovery facility may be a process streamfrom one or more of the facilities discussed herein, including, forexample, at least one of a solvolysis facility, a pyrolysis facility, acracker facility, a POX gasification facility, a solidificationfacility. The energy recovery facility 80 may be in a separategeographical area or in its own separate facility, while, in one or moreother embodiments, at least a portion of the energy recovery facility 80may be located in or near one of the other facilities. For example, anenergy recovery facility 80 within a chemical recycling facility 10 asshown in FIG. 1 may include an energy recovery furnace in the solvolysisfacility and another energy recovery furnace in a POX gasificationfacility.

Other Processing Facilities

In an embodiment or in combination with any embodiment mentioned herein,the chemical processing facility 10 generally shown in FIG. 1 mayinclude at least one other type of downstream chemical recyclingfacility and/or one or more other systems or facilities for processingone or more of the chemical recycling product or coproduct streams.Examples of suitable types of other facilities can include, but are notlimited to, a solidification facility and a product separation facility.Additionally, at least a portion of one or more streams may betransported or sold to an end user or customer, and/or at least aportion of one or more streams may be sent to a landfill or otherindustrial disposal site.

Solidification Facility

In an embodiment or in combination with any embodiment mentioned herein,the chemical recycling facility 10 may also comprise a solidificationfacility. As used herein, the term “solidification” refers to causing anon-solid material to become a solid material through a physical means(e.g., cooling) and/or chemical means (e.g., precipitation). A“solidification facility” is a facility that includes all equipment,lines, and controls necessary to carry out solidification of a feedstockderived from waste plastic.

A feed stream introduced into the solidification facility may originatefrom one or more locations within the chemical recycling facility 10.For example, the feed stream to the solidification facility may compriseat least one of one or more solvolysis coproduct streams, a stream fromthe pyrolysis facility including pyrolysis oil (pyoil) and/or pyrolysisresidue, a predominantly liquid stream from one or more facilities, andcombinations thereof. Definitions for pyrolysis oil and pyrolysisresidue are provided herein. One or more of these streams may beintroduced into the solidification facility continuously or one or moreof these streams may be introduced intermittently. When multiple typesof feed streams are present, each may be introduced separately, or all,or a portion, of the streams may be combined so that the combined streammay be introduced into the solidification facility. The combining, whenperformed, may take place in a continuous or batch manner.

The solidification facility may include a cooling zone for cooling andat least partially solidifying the feed stream, followed by an optionalsize reduction zone. Upon leaving the cooling zone, all or a portion ofstream may be a solidified material. In some cases, the solidifiedmaterial can be in the form of sheets, blocks, or chunks, or it may bein the form of flakes, tablets, pastilles, particles, pellets,micropellets, or a powder. When the feed stream is only partiallysolidified, the stream withdrawn from the cooling zone may comprise botha solid and a liquid phase. At least a portion of the solid phase may beremoved and all or a portion of the liquid phase may be withdrawn fromthe solidification facility and introduced into another facility,optionally within the chemical recycling facility (such as, for example,the solvolysis facility).

In an embodiment or in combination with any embodiment mentioned herein,the solidification facility may also include a size reduction zone forreducing the size of the solid material and forming a plurality ofparticles. In an embodiment or in combination with any embodimentmentioned herein, the size reduction may include comminuting, smashing,breaking, or grinding/granulating larger pieces or chunks of solidifiedmaterial to form the particles. In other embodiments, at least a portionof the feed stream to the solidification facility may be at leastpartially cooled before being pelletized via conventional pelletizationdevices. Regardless of how the particles are formed, the resultingsolids can have an a D90 particle size of at least 50, at least 75, atleast 100, at least 150, at least 250, at least 350, at least 450, atleast 500, at least 750 microns, or at least 0.5, at least 1, at least2, at least 5, or at least 10 mm and/or not more than 50, not more than45, not more than 40, not more than 30, not more than 35, not more than30, not more than 25, not more than 20, not more than 15, not more than10, not more than 5, not more than 2, not more than 1 mm or not morethan 750, not more than 500, not more than 250, or not more than 200microns. The solids may comprise a powder. The solids may comprisepellets of any shape. The solids can have a recycle content of at least1, at least 5, at least 10, at least 15, at least 20, at least 25, atleast 30, at least 35, at least 40, at least 45, at least 50, at least55, at least 60, at least 65, at least 70, at least 75, at least 80, atleast 85, at least 90, or at least 95 weight percent, based on the totalweight of the solids.

The solids withdrawn from the solidification facility may be routed toone or more (or two or more) of the pyrolysis facility, the energyrecovery facility, and/or the POX gasification facility. The solids canbe in the form of solids or may be melted or otherwise at leastpartially liquified prior to or during transport. In some embodiments,the solids may be combined with a liquid to form a slurry and the slurrymay be introduced into one or more chemical recycling facilities asdescribed herein. Examples of suitable liquids can include, but are notlimited to, water, alcohols, and combinations thereof. In an embodimentor in combination with any embodiment mentioned herein, at least aportion of the solids can be heated to at least partially melt orliquify the solids and the resulting melt can be introduced into one ormore of facilities described above. Optionally, at least a portion ofthe solids may be sent to an industrial landfill (not shown).

Product Separation Facility

In an embodiment or in combination with any embodiment mentioned herein,at least a portion of one of the streams within the chemical recyclingfacility 10 shown in FIG. 1 may be separated in a product separationfacility (represented by numeral 90 in FIG. 1 ) to form a product streamsuitable for further sale and/or use. For example, at least a portion ofone or more of the solvolysis coproduct streams may be further processedin a separation zone to form one or more purified or refined productstreams. Examples of suitable processes used in the separation zone caninclude, but are not limited to, distillation, extraction, decanting,stripping, rectification, and combinations thereof. The refined streamsform the product separation zone can include at least 50, at least 55,at least 60, at least 65, at least 70, at least 75, at least 80, atleast 85, at least 90, or at least 95 weight percent of a desiredcomponent or components, based on the total weight of the refinedproduct stream. Examples of desired components can include certainalcohols or glycols (e.g., ethylene glycol, methanol), alkanes (e.g.,ethane, propane, and butane and heavier), and olefins (e.g., propylene,ethylene, and combinations).

Weight percentages expressed on the MPW are the weight of the MPW as fedto the first stage separation and prior to addition of anydiluents/solutions such as salt or caustic solutions.

In aspect 1, there is provided a method of recycling a plastic wastecomprising: (a) feeding a quantity of PET and metal-containing reclaimerco-product separated from the plastic waste to a chemical recyclingfacility; and (b) depolymerizing in the chemical recycling facility atleast a portion of the quantity of PET and metal-containing reclaimerco-product.

In aspect 2, there is provided a method of recycling a plastic wastecomprising: (a) feeding a quantity of PET and metal-containing reclaimerco-product separated from the plastic waste to a chemical recyclingfacility, the quantity of metal-containing co-product comprising plasticflakes and at least 0.1 weight percent metals; and (b) depolymerizing inthe chemical recycling facility at least a portion of the plasticflakes.

In aspect 3, there is provided a method of recycling a plastic wastecomprising: (a) feeding a quantity of PET and metal-containing reclaimerco-product separated from the plastic waste to a chemical recyclingfacility, the quantity of metal-containing co-product comprising plasticarticles and at least 0.1 weight percent metals; and (b) depolymerizingin the chemical recycling facility at least a portion of the plasticarticles.

In aspect 4, there is provided a method of recycling a plastic wastecomprising: (a) feeding a quantity of PET and metal-containing reclaimerco-product separated from the plastic waste to a chemical recyclingfacility, the quantity of metal-containing co-product comprising plasticfines and at least 0.1 weight percent metals; and (b) depolymerizing inthe chemical recycling facility at least a portion of the plastic fines.

In aspect 5, there is provided the use of a PET and metal-containingreclaimer co-product as a feedstock to a chemical recycling facility.

In aspect 6 of this disclosure, which can include, but is not limited toaspects 1-5, the quantity of PET and metal-containing reclaimerco-product comprises at least 0.1 weight percent metals.

In aspect 7 of this disclosure, which can include, but is not limited toaspects 1-6, the metals comprise one or more non-ferrous metals.

In aspect 8 of this disclosure, which can include, but is not limited toaspects 1-7, the non-ferrous metals comprise aluminum, copper, lead,nickel, tin, titanium, zinc, and/or alloys thereof.

In aspect 9 of this disclosure, which can include, but is not limited toaspects 1-8, the metals comprise one or more ferrous metals.

In aspect 10 of this disclosure, which can include, but is not limitedto aspects 1-9, the ferrous metals comprise iron, steel, stainlesssteel, carbon steel, austentic, martensitic, duplex stainless steels,ferritic stainless steel, and/or alloys thereof.

In aspect 11 of this disclosure, which can include, but is not limitedto aspects 1-10, the quantity of PET and metal-containing reclaimerco-product comprises at least 0.1 weight percent PET on a dry basis.

In aspect 12 of this disclosure, which can include, but is not limitedto aspects 1-11, the co-product does not undergo separation prior tosaid feeding to said chemical recycling facility (a).

In aspect 13 of this disclosure, which can include, but is not limitedto aspects 1-12, the method further comprises separating at least aportion of the plastic material in the co-product from the metals beforesaid depolymerizing (b).

In aspect 14 of this disclosure, which can include, but is not limitedto aspects 1-13, the separating comprises feeding at least a portion ofthe quantity of PET and metal-containing reclaimer co-product into atleast one density separation stage to separate the portion of plasticmaterials from the metals.

In aspect 15 of this disclosure, which can include, but is not limitedto aspects 1-14, the method further comprises separating at least aportion of the plastic flakes from the metals before said depolymerizing(b).

In aspect 16 of this disclosure, which can include, but is not limitedto aspects 1-15, the separating comprises feeding at least a portion ofthe quantity of PET and metal-containing reclaimer co-product into atleast one density separation stage to separate the portion of plasticflakes from the metals.

In aspect 17 of this disclosure, which can include, but is not limitedto aspects 1-16, the method further comprises feeding the portion of theplastic flakes into a solvolysis facility within the chemical recyclingfacility.

In aspect 18 of this disclosure, which can include, but is not limitedto aspects 1-17, the method further comprises feeding at least a portionof the metals separated from the plastic flake into a partial oxidation(POX) gasifier.

In aspect 19 of this disclosure, which can include, but is not limitedto aspects 1-18, the co-product does not undergo separation prior to thefeeding to said chemical recycling facility (a).

In aspect 20 of this disclosure, which can include, but is not limitedto aspects 1-19, the method further comprising feeding at least aportion of the metals and at least a portion of the plastic flakes inthe co-product to a solvolysis facility within said chemical recyclingfacility.

In aspect 21 of this disclosure, which can include, but is not limitedto aspects 1-20, at least a portion of the metals are removed from theco-product by a solid/liquid separator and/or purge in the solvolysisfacility.

In aspect 22 of this disclosure, which can include, but is not limitedto aspects 1-21, the plastic articles are in the form of compressedbales.

In aspect 23 of this disclosure, which can include, but is not limitedto aspects 1-22, the method further comprises processing at least aportion of the compressed bales to thereby produce a debaled quantity ofplastic articles and the metals.

In aspect 24 of this disclosure, which can include, but is not limitedto aspects 1-23, the processing comprises reducing the size of the balesto form a quantity of plastic particulate solids having a D90 particlesize of less than 2.54 cm (1 inch).

In aspect 25 of this disclosure, which can include, but is not limitedto aspects 1-24, the method further comprises separating at least aportion of the plastic articles and/or the plastic particulate solidsfrom the metals before the depolymerizing (b).

In aspect 26 of this disclosure, which can include, but is not limitedto aspects 1-25, the separating comprises feeding at least a portion ofthe plastic articles and/or the plastic particulate solids and themetals into at least one density separation stage to separate theportion of the plastic articles and/or the plastic particulate solidsfrom the metals.

In aspect 27 of this disclosure, which can include, but is not limitedto aspects 1-26, the method further comprises feeding at least a portionof the separated plastic articles and/or the separated plasticparticulate solids into a solvolysis facility within the chemicalrecycling facility.

In aspect 28 of this disclosure, which can include, but is not limitedto aspects 1-27, the method further comprises feeding at least a portionof the separated metals into a partial oxidation (POX) gasifier.

In aspect 29 of this disclosure, which can include, but is not limitedto aspects 1-28, the PET and metal-containing reclaimer co-product doesnot undergo separation prior to the feeding to the chemical recyclingfacility.

In aspect 30 of this disclosure, which can include, but is not limitedto aspects 1-29, the method further comprises feeding at least a portionof the metals and at least a portion of the plastic articles and/or theplastic particulate solids to a solvolysis facility within the chemicalrecycling facility.

In aspect 31 of this disclosure, which can include, but is not limitedto aspects 1-30, at least a portion of the metals are removed by filterand/or purge in the solvolysis facility.

In aspect 32 of this disclosure, which can include, but is not limitedto aspects 1-31, the method further comprises densifying at least aportion of the plastic fines to produce a quantity of densifiedPET-containing particles before the depolymerizing (b).

In aspect 33 of this disclosure, which can include, but is not limitedto aspects 1-32, the densified PET-containing particles have a D90particle size of 1 to 10 mm.

In aspect 34 of this disclosure, which can include, but is not limitedto aspects 1-33, the densified PET-containing particles comprise atleast a portion of the metals.

In aspect 35 of this disclosure, which can include, but is not limitedto aspects 1-34, the method further comprises feeding at least a portionof the densified PET-containing particles to a solvolysis facilitywithin the chemical recycling facility without undergoing apreprocessing or separation process.

In aspect 36 of this disclosure, which can include, but is not limitedto aspects 1-35, the method further comprises separating and/orrecovering at least a portion of the metals in the co-product in ametal-containing stream, and feeding the metal-containing stream to apyrolysis facility within the chemical recycling facility.

In aspect 37 of this disclosure, which can include, but is not limitedto aspects 1-36, the metal-containing stream further comprises aquantity of plastic material.

Definitions

It should be understood that the following is not intended to be anexclusive list of defined terms. Other definitions may be provided inthe foregoing description, such as, for example, when accompanying theuse of a defined term in context.

As used herein, the terms “a,” “an,” and “the” mean one or more.

As used herein, the term “and/or,” when used in a list of two or moreitems, means that any one of the listed items can be employed by itselfor any combination of two or more of the listed items can be employed.For example, if a composition is described as containing components A,B, and/or C, the composition can contain A alone; B alone; C alone; Aand B in combination; A and C in combination, B and C in combination; orA, B, and C in combination.

As used herein, the phrase “at least a portion” includes at least aportion and up to and including the entire amount or time period.

As used herein, the term “caustic” refers to any basic solution (e.g.,strong bases, concentrated weak bases, etc.) that can be used in thetechnology as a cleaning agent, for killing pathogens, and/or reducingodors.

As used herein, the term “centrifugal density separation” refers to adensity separation process where the separation of materials isprimarily cause by centrifugal forces.

As used herein, the term “chemical recycling” refers to a waste plasticrecycling process that includes a step of chemically converting wasteplastic polymers into lower molecular weight polymers, oligomers,monomers, and/or non-polymeric molecules (e.g., hydrogen, carbonmonoxide, methane, ethane, propane, ethylene, and propylene) that areuseful by themselves and/or are useful as feedstocks to another chemicalproduction process(es).

As used herein, the term “chemical recycling facility” refers to afacility for producing a recycle content product via chemical recyclingof waste plastic. A chemical recycling facility can employ one or moreof the following steps: (i) preprocessing, (ii) solvolysis, (iii)pyrolysis, (iv) cracking, and/or (v) POX gasification.

As used herein, the term “co-located” refers to the characteristic of atleast two objects being situated on a common physical site, and/orwithin one mile of each other.

As used herein, the term “colored plastic-containing mixture” refers to:(a) a plastic-containing material identified by a reclaimer or MRF as acolored plastic or identified by a reclaimer or MRF as non-clear rPET;or (b) any plastic-containing material separated by a reclaimer or MRFother than dry fines, wet fines, reclaimer clear rPET product, rocks,biomass, metal, or fiber.

As used herein, the terms “comprising,” “comprises,” and “comprise” areopen-ended transition terms used to transition from a subject recitedbefore the term to one or more elements recited after the term, wherethe element or elements listed after the transition term are notnecessarily the only elements that make up the subject.

As used herein, the term “conducting” refers to the transport of amaterial in a batchwise and/or continuous manner.

As used herein, the term “cracking” refers to breaking down complexorganic molecules into simpler molecules by the breaking ofcarbon-carbon bonds.

As used herein, the term “D90” refers to a specified diameter whereninety percent of a distribution of particles has a smaller diameterthan the specified diameter and ten percent has a larger diameter thanthe specified diameter. To ensure that a representative D90 value isobtained, the sample size of the particles should be at least one pound.To determine a D90 for particles in a continuous process, testing shouldbe performed on at least 5 samples that are taken at equal timeintervals over at least 24 hours. Testing for D90 is performed usinghigh-speed photography and computer algorithms to generate a particlesize distribution. One suitable particle size analyzer for determiningD90 values is the Model CPA 4-1 Computerized Particle Analyzer from W. STyler of Mentor, Ohio.

As used herein, the term “diameter” means the maximum chord length of aparticle (i.e., its largest dimension).

As used herein, “densifying” refers to a process of condensing andpelletizing, agglomerating, or partial melting a quantity of plasticparticles having a D90 particle size of less than 0.32 cm (⅛ inch) toform solid particulates (e.g., pellets) having a D90 particle size of0.32 cm (⅛ inch) to 2.54 cm (1 inch).

As used herein, the term “density separation process” refers to aprocess for separating materials based, at least in part, upon therespective densities of the materials. Moreover, the terms “low-densityseparation stage” and “high-density separation stage” refer to relativedensity separation processes, wherein the low-density separation has atarget separation density less than the target separation density of thehigh-density separation stage.

As used herein, the term “depleted” refers to having a concentration (ona dry weight basis) of a specific component that is less than theconcentration of that component in a reference material or stream.

As used herein, the term “directly derived” refers to having at leastone physical component originating from waste plastic.

As used herein, the term “dry fines” refers to waste plastic particlesfrom a PET reclaimer facility and/or a manufacturer of PET articles,having an average particle size of less than 0.32 cm (⅛ inch) and amoisture content of less than 2% by weight.

As used herein, the term “enriched” refers to having a concentration (ona dry weight basis) of a specific component that is greater than theconcentration of that component in a reference material or stream.

As used herein, the terms “filtration” and “filtering” and “filter(ed)”refer to processes and/or apparatuses for performing solid/liquidseparation, which includes, but is not limited to, the use of media,centrifugal separation, and/or settling.

As used herein, the term “halide” refers to a composition comprising ahalogen atom bearing a negative charge (i.e., a halide ion).

As used herein, the term “halogen” or “halogens” refers to organic orinorganic compounds, ionic, or elemental species comprising at least onehalogen atom.

As used herein, the terms “having,” “has,” and “have” have the sameopen-ended meaning as “comprising,” “comprises,” and “comprise” providedabove.

As used herein, the term “heavy organic methanolysis coproduct” refersto a methanolysis coproduct with a boiling point greater than DMT.

As used herein, the term “heavy organic solvolysis coproduct” refers toa solvolysis coproduct with a boiling point greater than the principalterephthalyl product of the solvolysis facility.

As used herein, the terms “including,” “include,” and “included” havethe same open-ended meaning as “comprising,” “comprises,” and “comprise”provided above.

As used herein, the term “indirectly derived” refers to having anassigned recycle content i) that is attributable to waste plastic, butii) that is not based on having a physical component originating fromwaste plastic.

As used herein, the term “isolated” refers to the characteristic of anobject or objects being by itself or themselves and separate from othermaterials, in motion or static.

As used herein, the term “light organic methanolysis coproduct” refersto a methanolysis coproduct with a boiling point less than DMT.

As used herein, the term “light organics solvolysis coproduct” refers toa solvolysis coproduct with a boiling point less than the principalterephthalyl product of the solvolysis facility.

As used herein, the term “methanolysis coproduct” refers to any compoundwithdrawn from a methanolysis facility that is not dimethylterephthalate (DMT), ethylene glycol (EG), or methanol.

As used herein, the terms “mixed plastic waste” and “MPW” refer to amixture of at least two types of waste plastics including, but notlimited to the following plastic types: polyethylene terephthalate(PET), one or more polyolefins (PO), and polyvinylchloride (PVC).

As used herein, the term “partial oxidation (POX)” or “POX” refers tohigh temperature conversion of a carbon-containing feed into syngas,(carbon monoxide, hydrogen, and carbon dioxide), where the conversion iscarried out in the presence of a less than stoichiometric amount ofoxygen. The feed to POX gasification can include solids, liquids, and/orgases.

As used herein, the term “partial oxidation (POX) reaction” refers toall reactions occurring within a partial oxidation (POX) gasifier in theconversion of a carbon-containing feed into syngas, including but notlimited to partial oxidation, water gas shift, water gas—primaryreactions, Boudouard, oxidation, methanation, hydrogen reforming, steamreforming, and carbon dioxide reforming.

As used herein, “PET” means a homopolymer of polyethylene terephthalate,or polyethylene terephthalate modified with modifiers or containingresidues or moieties of other than ethylene glycol and terephthalicacid, such as isophthalic acid, 1,4-cyclohexanedicarboxylic acid,diethylene glycol, TMCD (2,2,4,4-tetramethyl-1,3-cyclobutanediol), CHDM(cyclohexanedimethanol), propylene glycol, isosorbide, 1,4-butanediol,1,3-propane diol, and/or NPG (neopentyl glycol), or polyesters havingrepeating terephthalate units (and whether or not they contain repeatingethylene glycol based units) and one or more residues or moieties ofTMCD (2,2,4,4-tetramethyl-1,3-cyclobutanediol), CHDM(cyclohexanedimethanol), propylene glycol, or NPG (neopentyl glycol),isosorbide, isophthalic acid, 1,4-cyclohexanedicarboxylic acid,1,4-butanediol, 1,3-propane diol, and/or diethylene glycol, orcombinations thereof.

As used herein, the term “overhead” refers to the physical location of astructure that is above a maximum elevation of quantity of particulateplastic solids within an enclosed structure.

As used herein, the term “PET and metal-containing reclaimer co-product”refers to materials from a magnetic separator, an eddy currentseparator, or other metal separator in a PET reclaimer facility that arenot recovered as rPET product.

As used herein, the term “partial oxidation (POX) gasification facility”or “POX Facility” refers to a facility that includes all equipment,lines, and controls necessary to carry out POX gasification of wasteplastic and feedstocks derived therefrom.

As used herein, the term “partially processed waste plastic” means wasteplastic that has been subjected to at least on automated or mechanizedsorting, washing, or comminuted step or process. Partially processedwaste plastics may originate from, for example, municipal recyclingfacilities (MRFs) or reclaimers. When partially processed waste plasticis provided to the chemical recycling facility, one or morepreprocessing steps may me skipped.

As used herein, the term “PET solvolysis” refers to a reaction by whicha polyester terephthalate-containing plastic feed is chemicallydecomposed in the presence of a solvent to form a principal terephthalylproduct and/or a principal glycol product.

As used herein, the term “physical recycling” (also known as “mechanicalrecycling”) refers to a waste plastic recycling process that includes astep of melting waste plastic and forming the molten plastic into a newintermediate product (e.g., pellets or sheets) and/or a new end product(e.g., bottles). Generally, physical recycling does not substantiallychange the chemical structure of the plastic, although some degradationis possible.

As used herein, the term “plastic articles” refers to baled or unbaledplastic materials having a D90 particle size of greater than 2.54 cm (1inch).

As used herein, the term “plastic fines” refers to plastic particulateshaving a D90 particle size of less than 0.32 cm (⅛ inch).

As used herein, the term “plastic flakes” refers to plastic particleshaving a D90 particle size of 0.32 cm (⅛ inches) to 2.54 cm (1 inch).

As used herein, the term “predominantly” means more than 50 percent byweight. For example, a predominantly propane stream, composition,feedstock, or product is a stream, composition, feedstock, or productthat contains more than 50 weight percent propane.

As used herein, the term “preprocessing” refers to preparing wasteplastic for chemical recycling using one or more of the following steps:(i) comminuting, (ii) particulating, (iii) washing, (iv) drying, and/or(v) separating.

As used herein, the term “pyrolysis” refers to thermal decomposition ofone or more organic materials at elevated temperatures in an inert(i.e., substantially oxygen free) atmosphere.

As used herein, the term “pyrolysis char” refers to a carbon-containingcomposition obtained from pyrolysis that is solid at 200° C. and 1 atm.

As used herein, the term “pyrolysis gas” refers to a compositionobtained from pyrolysis that is gaseous at 25° C.

As used herein, the term “pyrolysis heavy waxes” refers to C20+hydrocarbons obtained from pyrolysis that are not pyrolysis char,pyrolysis gas, or pyrolysis oil.

As used herein, the terms “pyrolysis oil” or “pyoil” refers to acomposition obtained from pyrolysis that is liquid at 25° C. and 1 atm.

As used herein, the term “pyrolysis residue” refers to a compositionobtained from pyrolysis that is not pyrolysis gas or pyrolysis oil andthat comprises predominantly pyrolysis char and pyrolysis heavy waxes.

As used herein, the term “reclaimer co-product” refers to any materialseparated or recovered by the reclaimer facility that is not recoveredas a clear rPET product, including colored rPET.

As used herein, “reclaimer flake reject” refers to a waste mixture ofplastic, comprising at least PET and at least 0.1 weight percent PVC ona dry basis, from a reclaimer facility and having a D90 particle size of0.32 cm (⅛ inch) to 2.54 cm (1 inch).

As used herein, “reclaimer wet fines” refers to a stream or batch ofPET-containing plastic particles separated from a waste plastic within areclaimer facility and having a water content, when first isolated fromthe waste plastic within the reclaimer facility, of at least 2% byweight based upon the total weight of the reclaimer wet fines, and theplastic particles have a D90 of less than 0.32 cm (⅛ inch).

As used herein, the term “recycle content” and “r-content” refer tobeing or comprising a composition that is directly and/or indirectlyderived from waste plastic.

As used herein, the term “resin ID code” refers to the set of symbolsand associated number (1 through 7) appearing on plastic products thatidentify the plastic resin out of which the product is made, developedoriginally in 1988 in the United States but since 2008 has beenadministered by ASTM International.

As used herein, the term “resin ID code 1” refers to plastic productsmade from polyethylene terephthalate (PET). Such plastic products mayinclude soft drink bottles, mineral water bottles, juice containers, andcooking oil containers.

As used herein, the term “resin ID code 2” refers to plastic productsmade from high-density polyethylene (HDPE). Such plastic products mayinclude milk jugs, cleaning agent and laundry detergent containers,shampoo bottles, and soap containers.

As used herein, the term “resin ID code 3” refers to plastic productsmade from polyvinyl chloride (PVC). Such plastic products may includefruit and sweets trays, plastic packing (bubble foil), and food wrap.

As used herein, the term “resin ID code 4” refers to plastic productsmade from low-density polyethylene (LDPE). Such plastic products mayinclude shopping bags, light weight bottles, and sacks.

As used herein, the term “resin ID code 5” refers to plastic productsmade from polypropylene (PP). Such plastic products may includefurniture, auto parts, industrial fibers, luggage, and toys.

As used herein, the term “resin ID code 6” refers to plastic productsmade from polystyrene (PS). Such plastic products may include toys, hardpacking, refrigerator trays, cosmetic bags, costume jewelry, CD cases,vending cups, and clamshell containers.

As used herein, the term “resin ID code 7” refers to plastic productsmade from plastics other than those defined as resin ID codes 1-6,including but not limited to, acrylic, polycarbonate, polyactic fibers,nylon, and fiberglass. Such plastic products may include bottles,headlight lenses, and safety glasses.

As used herein, the term “separation efficiency” refers to the degree ofseparation between at two or more phases or components as defined inFIG. 10 .

As used herein, the term “sink-float density separation” refers to adensity separation process where the separation of materials isprimarily caused by floating or sinking in a selected liquid medium.

As used herein, the term “solidified purge material” refers to a plasticwaste removed from any molten polymer processing apparatus or portionthereof while the apparatus is not producing an intended product (e.g.,pellets, bottles, and other plastic articles), including but not limitedto an extruder, filter, pelletizer, reactor, conduit, and the like, thatwas molten within the molten polymer processing apparatus but waspermitted to solidify outside of said apparatus.

As used herein, the term “solvolysis” or “ester solvolysis” refers to areaction by which an ester-containing feed is chemically decomposed inthe presence of a solvent to form a principal carboxyl product and/or aprincipal glycol product. Examples of solvolysis include, hydrolysis,alcoholysis, and ammonolysis.

As used herein, the term “solvolysis coproduct” refers to any compoundwithdrawn from a solvolysis facility that is not the principal carboxyl(terephthalyl) product of the solvolysis facility, the principal glycolproduct of the solvolysis facility, or the principal solvent fed to thesolvolysis facility.

As used herein, the term “sorted plastic-containing mixture” refers to aquantity of mixed plastic waste sorted by a consumer and left forcollection at a curbside or at a central convenience station, and maycomprise clear and/or colored plastic articles, or sorted by a trashcollector or municipality.

As used herein, the term “terephthalyl” refers to a molecule includingthe following group:

As used herein, the term “principal terephthalyl” refers to the main orkey terephthalyl product being recovered from the solvolysis facility.

As used herein, the term “glycol” refers to a component comprising twoor more —OH functional groups per molecule.

As used herein, the term “principal glycol” refers to the main glycolproduct being recovered from the solvolysis facility.

As used herein, the term “target separation density” refers to a densityabove which materials subjected to a density separation process arepreferentially separated into the higher-density output and below whichmaterials are separated in the lower-density output.

As used herein, the terms “waste plastic” and “plastic waste” refer toused, scrap, and/or discarded plastic materials. The waste plastic fedto the chemical recycling facility may be unprocessed or partiallyprocessed.

As used herein, the term “unprocessed waste plastic” means waste plasticthat has not be subjected to any automated or mechanized sorting,washing, or comminuting. Examples of unprocessed waste plastic includewaste plastic collected from household curbside plastic recycling binsor shared community plastic recycling containers.

As used herein, the phrase “at least a portion” includes at least aportion and up to and including the entire amount or time period.

As used herein, the term “waste plastic particulates” refers to wasteplastic having a D90 of less than 1 inch.

As used herein, the term “predominantly” means at least 50 weightpercent of something, based on its total weight. For example, acomposition comprising “predominantly” component A includes at least 50weight percent of component A, based on the total weight of thecomposition.

As used herein, “downstream” means a target unit operation, vessel, orequipment that:

a. is in fluid (liquid or gas) communication, or in pipingcommunication, with an outlet stream from the radiant section of acracker furnace, optionally through one or more intermediate unitoperations, vessels, or equipment, or

b. was in fluid (liquid or gas) communication, or in pipingcommunication, with an outlet stream from the radiant section of acracker furnace, optionally through one or more intermediate unitoperations, vessels, or equipment, provided that the target unitoperation, vessel, or equipment remains within the battery limits of thecracker facility (which includes the furnace and all associateddownstream separation equipment).

CLAIMS NOT LIMITED TO DISCLOSED EMBODIMENTS

The preferred forms of the invention described above are to be used asillustration only and should not be used in a limiting sense tointerpret the scope of the present invention. Modifications to theexemplary embodiments, set forth above, could be readily made by thoseskilled in the art without departing from the spirit of the presentinvention.

The inventors hereby state their intent to rely on the Doctrine ofEquivalents to determine and assess the reasonably fair scope of thepresent invention as it pertains to any apparatus not materiallydeparting from but outside the literal scope of the invention as setforth in the following claims.

1. A method of recycling a plastic waste comprising: (a) feeding aquantity of PET and metal-containing reclaimer co-product separated fromsaid plastic waste to a chemical recycling facility; and (b)depolymerizing in said chemical recycling facility at least a portion ofsaid quantity of PET and metal-containing reclaimer co-product.
 2. Amethod of recycling a plastic waste comprising: (a) feeding a quantityof PET and metal-containing reclaimer co-product separated from saidplastic waste to a chemical recycling facility, said quantity ofmetal-containing co-product comprising plastic flakes and at least 0.1weight percent metals; and (b) depolymerizing in said chemical recyclingfacility at least a portion of said plastic flakes; or (b)depolymerizing in said chemical recycling facility at least a portion ofsaid plastic articles.
 3. (canceled)
 4. The method of claim 2, whereinsaid plastic articles are in the form of compressed bales.
 5. The methodof claim 4, further comprising processing at least a portion of saidcompressed bales to thereby produce a debaled quantity of plasticarticles and said metals.
 6. The method of claim 5, wherein saidprocessing comprises reducing the size of said bales to form a quantityof plastic particulate solids having a D90 particle size of less than2.54 cm (1 inch).
 7. The method of any one of claim 1 or 2, wherein saidco-product does not undergo separation prior to said feeding to saidchemical recycling facility (a).
 8. The method of claim 7, furthercomprising: (i) feeding at least a portion of said metals and at least aportion of said plastic material in said co-product to a solvolysisfacility within said chemical recycling facility; (ii) feeding at leasta portion of said metals and at least a portion of said plastic flakesin said co-product to a solvolysis facility within said chemicalrecycling facility; or (iii) feeding at least a portion of said metalsand at least a portion of said plastic articles in said co-productand/or said plastic particulate solids to a solvolysis facility withinsaid chemical recycling facility.
 9. The method of claim 8, wherein atleast a portion of said metals are removed from said co-product and/orsaid plastic particulate solids by a solid/liquid separator and/or purgein said solvolysis facility.
 10. The method of any one of claim 1 or 2,further comprising: (i) separating at least a portion of the plasticmaterial in said co-product from said metals before said depolymerizing(b); (ii) separating at least a portion of said plastic flakes from saidmetals before said depolymerizing (b); or (iii) separating at least aportion of said plastic articles and/or said plastic particulate solidsfrom said metals before said depolymerizing (b).
 11. The method of claim10, wherein said separating comprises: (i) feeding at least a portion ofsaid quantity of PET and metal-containing reclaimer co-product into atleast one density separation stage to separate said portion of plasticmaterials from said metals; (ii) feeding at least a portion of saidquantity of PET and metal-containing reclaimer co-product into at leastone density separation stage to separate said portion of plastic flakesfrom said metals; or (iii) feeding at least a portion of said plasticarticles and/or said plastic particulate solids and said metals into atleast one density separation stage to separate said portion of saidplastic articles and/or said plastic particulate solids from saidmetals.
 12. The method of claim 10, further comprising feeding at leasta portion of said metals separated from said plastic material, saidplastic flake, said plastic articles, and/or said plastic particulatesolids into a partial oxidation (POX) gasifier.
 13. A method ofrecycling a plastic waste comprising: (a) feeding a quantity of PET andmetal-containing reclaimer co-product separated from said plastic wasteto a chemical recycling facility, said quantity of metal-containingreclaimer co-product comprising plastic fines and at least 0.1 weightpercent metals; and (b) depolymerizing in said chemical recyclingfacility at least a portion of said plastic fines.
 14. The method ofclaim 13, further comprising densifying at least a portion of saidplastic fines to produce a quantity of densified PET-containingparticles before said depolymerizing (b).
 15. The method of claim 14,wherein said densified PET-containing particles have a D90 particle sizeof 1 to 10 mm.
 16. The method of claim 14, wherein said densifiedPET-containing particles comprise at least a portion of said metals. 17.The method of claim 14, further comprising feeding at least a portion ofsaid densified PET-containing particles to a solvolysis facility withinsaid chemical recycling facility without undergoing a preprocessing orseparation process.
 18. The method of claim 13, further comprisingseparating and/or recovering at least a portion of said metals in saidco-product in a metal-containing stream, and feeding saidmetal-containing stream to a pyrolysis facility within said chemicalrecycling facility.
 19. The method of claim 18, wherein saidmetal-containing stream further comprises a quantity of plasticmaterial.
 20. The use of a PET and metal-containing reclaimer co-productas a feedstock to a chemical recycling facility.